Motor Swap: 1150 into an 1100EZ

[blackhammer]

Ive just done this motor swap as well, i used all my 1100 covers on the 1150, trimmed up the gear selector shaft hole as i thought that would be a neater finish than cutting into the 1150 cover.
If its already been mentioned sorry, but if your not using the 1150 with an oil cooler make sure you put the 1100 filter cover on it.

[CivilRock]

Well, I looked long and hard at both CS covers and decided I wanted to modify the 1150 cover to work. My 1100 cover is polished, and I just sold the motor and it really needs to stay with the bike. Plus I think I can cut the cover and make it look factory.

I guess I failed to mention that I built a DIY reverse shift (GP Shift) adapter and I think it makes the swap line up better than it would have been without it. I can see how the angles would have been a little too much.

Anyway, the cover is modified, and in place, and I'm very happy with the results.

-Kevin

[posplayr]

Looks good

[Carter Turk]

Are you using the 1150 front rubber mounted engine brackets? I don't think they fit without modification, but makes a huge difference in vibration damping. I guess it's the larger 18mm wrist pins that make it vibrate more than a 1100.

[chef1366]

Are you using the 1150 front rubber mounted engine brackets? I don't think they fit without modification, but makes a huge difference in vibration damping. I guess it's the larger 18mm wrist pins that make it vibrate more than a 1100.

I put an 83 motor in an 1150 and the rubber mounts fit fine.
I didn't know the 20mm wrist pins vibrated less.

[Carter Turk]

Guess I got my mm wrong. I meant the 1150 had larger ones than the 1100. My 1150 front mount brackets did not fit my 83 Katana frame. I had to graft the rubber mount portion on to the stock Katana bracket.

[CivilRock]

I just used the mounting brackets that I have with the 1100. There's 6? mounting points, I'm amazed that rubber front brackets would make a difference.

I guess if I find that the vibration is excessive, I'll look into it. Do you have a picture of the mounts for me to check out? I'd like to see the difference.

-Kevin

[Carter Turk]

I'll snap a photo tomorrow. Don't think I have stock 83 brackets anymore, only the modified ones.

[gs11ezrydr]

Are you using the 1150 front rubber mounted engine brackets? I don't think they fit without modification, but makes a huge difference in vibration damping. I guess it's the larger 18mm wrist pins that make it vibrate more than a 1100.

Correction The 1100's have 18mm wrist pins and the 1150's have 20 mm wrist pins Probably just a typo. Is a possibility though with larger parts going up and down. But never heard any one mention that aspect. This is one for the jury.

[Carter Turk]

Here's a shot with rubber mount grafted onto stock bracket

Second shot is the distance between mounting holes. Looks to be 2 5/8", where the 1150 bracket in the 3rd picture is about 2"


Also the fact Suzuki added the rubber mounts to 1150's, must mean they were aware of it too.

[blackhammer]

Great job, looks very neat.

i haven't used rubber mounts, just the standard 1100 ones, didn't notice the vibration to be too bad in my limited riding time so far. Might have to look into it if you guys find it makes a big difference.

[gmansyz]

Hiya
It is more the balance factor and how straight the crank is. Also, if the clutch basket is balanced as well.
Laters
Greg

[CivilRock]

Picture update

Mounted and wired in my new clocks. Bandit 400.


Mounted new coils, cut/crimped wires, threaded new leads in frame:


Mounted new Dyna 2000 and raised battery 3.625". - Removing the airbox created a lot of new space and I never liked how the battery hung down. Now you can't see it.


Overall view, trying to show the raised battery box. This pic would make more sense with the side covers on. And maybe a "before" pic.


So I bought this set of controls from a Burgman hoping to use the numerous buttons for stuff: changing ignition curves, turning off the lights (stealth mode), smoke screen, oil slick, etc. but the thing is huge, and I'm not going to use it.


I already ordered some GSXR controls.

-Kevin

[posplayr]

Hiya
It is more the balance factor and how straight the crank is. Also, if the clutch basket is balanced as well.
Laters
Greg

Yes I would hope the engines are balanced and it is more of a tolerance issue than imbalance issue.

[CivilRock]

16mm to 14mm oil cooler adapters

So I was planning on just buying some 14mm banjo fittings for the oil in/out ports on the motor and buying some hose and making use of what I could that came with the used 1995 Katana 600 oil cooler that I bought from ebay. The problem is that the Katana is all 16mm banjo bolts, and the 1150 is 14mm.

I had to buy one 10mm double banjo bolt to correct my brake set up, and it cost me $16. ($8 for the bolt, $8 for shipping) and it left a bad taste in my mouth. I also spent about 3 hours looking for a male 14mm to female 16mm adapter online with no results. So I took a gamble on a little idea I had to just make one.

I bought two 16mm x 1.5 nuts, and two 14mm x 1.5 bolts, and hoped that my drill bits would be strong enough to punch a hole through the length of the bolt.
It worked awesome. (Back in my supermoto days one of my friends GAVE me this mini lathe if I would fabricate him some wheel spacers. He couldn't figure out how to make it work. I have found just a ton of uses for this lathe, and I love it.)

Drilling out the bolt centers on the mini lathe:


The boring:


The other end:


Welded to the bolts:


The finished adapters:


In practice:


-Kevin