1981 1100E camshaft/caps question

[Guest]

Greetings. This is my first post, and it concerns my third GS1100 (two 81s and an 82). I never did much to the first two, but my current 81 (Old Blue) demands attention, so; I replaced the head gasket, then spent three days trying to time it with following inaccurate instructions. Finally got that figured out, started bolting down the cams, following the factory manual steps, and managed to crack one of the camshaft caps. These are apparently hard to come by. A friend advised me that the caps cannot be purchased new, and used caps aren't going to fit new cams. I cannot help but wonder how this can be accurate, since there are more aftermarket engine parts for this thing than one can imagine.
A hint on direction here would be great. I just want it to run "normal" for now.

Thanks.
Zod

[posplayr]

The cam caps are numbered and line bored. Not sure what you did to break one?? Are you on inch lbs or ft lbs with that torque wrench?

If you can find one it will fit, and you might be able to use some 600 or 800 grit to try and lap it in if it make teh cam stiff to turn. You would need to do that with valve springs removed.

[rphillips]

Each of those caps are machined to fit one particular location on one particular head. If you put your right front on your right rear, or your right front on the right front of my head, anywhere that's not where it was machined to go, it may be fine, but may not. But that particular cap is only machined to fit that one location on that one head.... I think, Thanks for that question, I'll be watching to hear from others who have been there & done that. But that's my understanding.

[Rijko]

Each of those caps are machined to fit one particular location on one particular head. If you put your right front on your right rear, or your right front on the right front of my head, anywhere that's not where it was machined to go, it may be fine, but may not. But that particular cap is only machined to fit that one location on that one head.... I think, Thanks for that question, I'll be watching to hear from others who have been there & done that. But that's my understanding.

you're right.
But they made those in large batches so many will be more or less the same.
I got lucky several times matching cam caps to heads.
The procedure to check (Plastigage) is described in the manual.

[GregT]

you're right.
But they made those in large batches so many will be more or less the same.
I got lucky several times matching cam caps to heads.
The procedure to check (Plastigage) is described in the manual.

The later the motor, the luckier you'll get. Current CNC production machining has effectively eliminated variations between parts.
The GSX series isn't too bad for swapping cam caps. Some hand scraping or an align hone is often all that's needed.
Early GSXR's are better again.

[Zod]

The line bored camshafts are something I'm not familiar with. The cracked cap is the result of too much frustration and the seventh time I had attempted to set the valves properly as a result of incorrect information regarding the process. If (when) I break something, I accept it as my mistake and pay for it. Of course, if someone helped me, I still pay for it. I have a head spotted, complete with cams and caps, for 150.00 to my door. I may just pick it up. I still don't know how you can purchase aftermarket cams and place them.
Thanks for your quick response.
Zod

[storm 64]

For $150 bucks I'd get the new head. Spend so time cleaning it up and you should be good. Also get yourself a service manual. Suzuki manuals are great but a Clymer's is also okay. If you need help we (I) can walk you through it. If you get frustrated, step back, sleep on it. That's what I do. Good luck 👍

[Rijko]

Greetings. This is my first post

Welcome here, btw !