1980 GS1100E - completing the build

[astroboiler]

I pretty certain that fiber plates should never touch one another.

Yep, looks like I was short one steel plate. Thanks for your reply.

I ordered a genuine Suzuki steel clutch plate and that came in last weekend. I soaked the fiber plates in the oil that I drained from this bike when I took it apart in the fall (I knew I was hanging onto it for some reason) and put the fibers and plates in the basket.



Also per the FSM I coated with Permatex ultra gray the normal faces where the cases meet in the clutch, rotor, and ignition areas. I started torquing down the clutch spring bolts, and snapped one of them off.



Fortunately I was able to extract this one with needle nose pliers. I wonder if 37 years of tension from the spring caused fatigue? I wouldn't think 8.5 ft.lbs of torque would be the culprit.



The threads were still in good shape, so I got a replacement 6mmx30mm screw and torqued all 6 incrementally to 104 in.lbs.



I picked up a Dyna-S ignition module last week too. I have the green 3.0 ohm Dyna coils already on the bike and they work great. My plan is to get the bike running again with the new Keihin CR Specials and the stock ignition plate (minimize the variables ya know?) before installing the Dyna-S. Next will be getting the pistons back on the rods and installing the block.

[astroboiler]

I got the piston rings in their correct positions, oiled the big and small ends of the rods, lightly oiled the pistons and put them back on the rods. Special care was taken to not drop the piston circlips down into the crank case.



When I bought all the nuts and bolts and gaskets from partzilla, I didn't think about replacing the base gasket or the cylinder sleeve o-rings. But I have placed an order for these and should have them soon. I had the motor disassembled this far last year right when I bought the bike, so from this point forward I feel confident. Degreeing the cams in my new slotted sprockets will be new for me and I have never played around with Keihin CR Specials either, so I'm looking forward to this.

[cbxchris]

Boy, does that bring back memories. Great engines. When I was looking at your cases I sat and thought of all the work a good set of drag racing cases had in them set up for a 3 speed. Sadly, I must say the Z-1 was better but not performance wise until the billet heads.