Extra parts during engine rebuild

[Nessism]

I’m rebuilding a chain drive 8V 1000 engine and have a few left over washers – bottom end is together. Been though the parts fishe and can’t figure out where these parts go. One thing that confuses the situation is that I parted out a 1000G, including removing the clutch and all the associated parts.

Anyone care to speculate what these extra parts are from? The large washer was definitely in the pile with the clutch parts – hoping it’s from G.

[Fishman]

Ed, that large washer looks like the one that holds the whole 1000 engine together. It goes right there in the middle of the bottom part of the engine. Sorry.

In all seriousness, I'm glad I'm not the only one with leftover parts when I put something back together. It doesn't happen often, but when it does, it's really bothersome.

Hope yours is just a washer for a footpeg or something. Alternatively, maybe one of your "friends" dropped a couple of washers in there while over drinking beer and are still laughing about it. . . hey this is starting to sound familiar to me now. . .

[hampshirehog]

Way to go Ed - losing weight like that. The big gain is to lose the wheels

Only things I can think of are the (27.95mm) washer on the gear shift shaft, behind the circlip or the washer that sits between the clutch thrust bearing and the clutch pressure disc.

I'm pretty sure the big one ain't from a 1000S.

[posplayr]

Washers

Ed,
The smaller ones look like ones that go to either side of the starter idler gear on my ED. There are several places where Suzuki seemed to do that; found the same in a transmission I was looking are as well as in the clutch.

That might help, but not what you wanted to hear. IMHO the big Chrome one is not likely from inside the engine/cases.

One more worrisome thing is the ED has an extra washer in the clutch that is not shown in the micro fiche. If you leave it out there is no problem as you will not get out of the driveway.

Jim

[Nessism]

That thin washer is much larger than the ones on the idler gear (my bike has two of those installed by the way). On the transmission shaft is a possibility though.

The large washer fits over the transmission shaft perfectly. I'm going to have a close look at the G bike engine to see if that large washer belongs there.

[rcp]

Hi Ed,

I've got a 78 GS1000 clutch and an 81 GS1000G clutch all disassembled, neatly organized and boxed. So I should be able to confirm tonight if the big washer is from the G.

I'll try to match the smaller ones too.

- Richard

[rcp]

Ed,
Your washer doesn't match anything in my GS1000G clutch. It has the same two washers as the GS1000: a 50mmOD/25mmID behind the oil pump gear, and a 65mmOD/25mmID between basket and hub.

The large one doesn't look like steel you'd find inside the engine - in the photo it looks like a stamped commercial one. Mixed in where it doesn't belong, or possibly a homebrew fix for something missing from one of the engines?

None of them belong with a 1000 transmission.

- Richard

[chef1366]

Did you mislabel the coffee can?

[Nessism]

Did you mislabel the coffee can?

I was fairly careful when taking the engine apart; put all the parts from the clutch cavity into the same box for example. Problem set in with the parted out bike, and my attempt to switch parts between them. An then there is the matter of drinking beer while working on the engine internals - not recommended.

At any rate, Richard supported my thought that none of those parts fit in the clutch. Not sure what else to consider now though.

[posplayr]

Did you mislabel the coffee can?

I like to just throw every thing into a pile in the middle of the floor.

[chef1366]

I like to just throw every thing into a pile in the middle of the floor.

I know

[BadBillyB]

Anyone care to speculate what these extra parts are from? The large washer was definitely in the pile with the clutch parts – hoping it’s from G.

The 28mm one is used on the release rack for the clutch. It is what the "torrington" style bearing rides on. If one side is way smoother than the other, put that side toward the bearing.....Billy

[Nessism]

The 28mm one is used on the release rack for the clutch. It is what the "torrington" style bearing rides on. If one side is way smoother than the other, put that side toward the bearing.....Billy

I was thinking that myself but the ID on the washer is too big - checked it last night.