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Well im finally getting around to fixing my 5th gear problem. Can i split the cases without taking the rest of the engine apart?
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Yes you can.Ed
To measure is to know.
Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182
Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846
Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf
KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection -
Awesome. Anyone have any tips or things to watch out for before i dive in?Comment
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Get an engine stand. Makes it so much easier.
When splitting have it upside down so the tranny doesn't fall out.1983 GS 1100E w/ 1230 kit, .340 lift Web Cams, Ape heavy duty valve springs, 83 1100 head with 1.5mm oversized SS intake valves, 1150 crank, Vance and Hines 1150 SuperHub, Star Racing high volume oil pump gears, 36mm carebs Dynojet stage 3 jet kit, Posplayr's SSPB, Progressive rear shocks and fork springs, Dyna 2000, Dynatek green coils and Vance & Hines 4-1 exhaust.
1985 GS1150ES stock with 85 Red E bodywork.
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Get a workshop manual that you can download, read it. then read it again.. No such thing as stupid questions, only stupid people.Comment
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FIRST, get a SUZUKI manual, NOT a Clymer or Haynes!! You don't need an engine stand, just a sturdy table to support the weight of the engine. Drain the oil & take the motor out of the bike. Pull the starter & upper case half bolts (make SURE you get ALL of them!). Pull the clutch hub & the 2 plates behind it that hold the cases halves together. You will need an impact driver for the Phillips head screws on these 2 plates. Remove the small "Z" shape plate in the countershaft area that holds the case halves together. Remove the stator & ignition covers & the ignition plate. Turn the engine upside down & remove the oil pan. Remove ALL of the lower case half bolts & then the cases will be ready to split. Feel free to call me at 714--356-784 five if you need help. I have been building & racing the 1100s & 1150s since they came out. Easy job!
Ray.Last edited by rapidray; 04-13-2015, 03:15 PM.Comment
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Found the output shaft fork to be very worn and showing signs of heat.Comment
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3rd gear( I believe its 3rd) has a lot of damage to the teeth and dogsComment
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Was it caused by a bent shift fork?Comment
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I cant figure out how to get all the pics in one post. SorryComment
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Another of the forkComment
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Ed
To measure is to know.
Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182
Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846
Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf
KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-ResurrectionComment
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Plugged oil port1983 GS 1100E w/ 1230 kit, .340 lift Web Cams, Ape heavy duty valve springs, 83 1100 head with 1.5mm oversized SS intake valves, 1150 crank, Vance and Hines 1150 SuperHub, Star Racing high volume oil pump gears, 36mm carebs Dynojet stage 3 jet kit, Posplayr's SSPB, Progressive rear shocks and fork springs, Dyna 2000, Dynatek green coils and Vance & Hines 4-1 exhaust.
1985 GS1150ES stock with 85 Red E bodywork.
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How do you figure? Where all the burn is in his pictures are all splash fed areas? I would replace all the shift forks, & shift fork shafts if they are bent, & the damaged gears.Originally posted by chef1366 View Post
Ray.Comment
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So that is from a bent fork? Looks like oil starvation.Originally posted by rapidray View Post1983 GS 1100E w/ 1230 kit, .340 lift Web Cams, Ape heavy duty valve springs, 83 1100 head with 1.5mm oversized SS intake valves, 1150 crank, Vance and Hines 1150 SuperHub, Star Racing high volume oil pump gears, 36mm carebs Dynojet stage 3 jet kit, Posplayr's SSPB, Progressive rear shocks and fork springs, Dyna 2000, Dynatek green coils and Vance & Hines 4-1 exhaust.
1985 GS1150ES stock with 85 Red E bodywork.
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