.png "Powered by vBulletin")
1983 GS1100ES Engine Rebuild.
Well, my winter project is well underway and progressing fairly well, taking into consideration work, kids, and all the other joys of life that keep us out of the garage...
I'm the proud owner of two 83 GS1100s.
My first is a 1100E with a little over 32k on the clock. It's stock with the exception of a sprocket conversion and a 4-1 kerker.
My Second is the 1100ES blue/white paint scheme with a little over 19k on the clock. Upgrades included, a 4-1 exhaust, stainless break lines, sprocket conversion, and jet kit with pod filters.
It's standing bare at the moment in my single car garage.
Initially, I was not planning on doing a total rebuild on the engine, however, I soon realized that i had a significant issue that needed to be addressed. I was originally planning on only removing the head and cylinder jugs to repair a nasty base gasket leak on the back side of the engine around cylinder 3/4. It did run great, with compression over all was good with cylinder 4 being slightly lower.
After removing the cylinders and cleaning up around the leak area i noticed some fine cracks along the webbing between cylinders 3 and 4.
The cracks spiderwebbed all the way down and there was noticeable movement. Additionally, when i was removing the sump and the strainer I found some fine metal shavings. The source of which was from a bolt of the incorrect length in the clutch cover that was rubbing and shearing on the clutch hub. (PO had the basket welded and I'm assuming that reassembly didn't go quit right.)
After consulting with a few friends and a great shop out my way, I determined that the only thing to do was to get new cases.
Many people would probably scrapped the project at this point and ebay'd/listed a part out, but I was always a bit more heard headed than most...not to mention I LOVE to see these gorgeous bikes out on the road.
Anywho, thanks to Fred over at Sky Cycles I was able to acquire a solid and clean set of cases which i further power washed/ brushed/ sanded as I am planning to bring the engine back to its OEM black glory upon reassembly.
I really enjoy doing these things by hand however sometimes i wish i had some better tools/equipment to really take the job to the next level. However, I'm happy with the outcome so far.
Currently, I'm awaiting some miscellaneous parts to continue on.
Things I've finished are:
1. Honed cylinders. Cleaned up nicely with good 45 degree crosshatching.
2. Pistons: Good shape, and cleaned up nicely, with new rings installed.
3. Lower and Upper Crankcase components installed including new cam chain:
Just waiting on new crank shaft oil seal, OEM O-rings, and gearbox plugs, then I should be ready to seal it up.
Things still on the list:
1. Going to be tackling the head next couple of days. Supposedly it had a valve adjustment done shortly before purchase, however i want to check guides, change seals, check retainers/springs/lap valves/etc... while I'm in there.
2. Rebuild clutch. The springs on the old hub were shimmed to prevent clutch rattle, then welded for strength. However, couple shims have some play and I've got a HD APE clutch kit so I think I'll be purchasing a new (used) hub to rebuild to go with the kit.
3. Reassembly and Paint.
WISH LIST:
1.GSXR suspension conversion.
I really envy some of you guys...A quick pick of my cluttered "work station," in my single car (or as the case may be duo bike) garage, located on the top of my portable table saw. And you might even be able to spot the every reliable and handy milk crates which are great stands and parts catches
.
I'll fill ya'll in on the rest of the project as it continues.
Just wanted to give a quick thanks to all of you on the site. I don't ever really post and only recently joined as a member on GSR, however I've been reading as an anonymous guest for quite some time and am thankful for all the knowledgeable and helpful people here on the forums!
Cheers and wish me luck.
Nic
I'm the proud owner of two 83 GS1100s.
My first is a 1100E with a little over 32k on the clock. It's stock with the exception of a sprocket conversion and a 4-1 kerker.
My Second is the 1100ES blue/white paint scheme with a little over 19k on the clock. Upgrades included, a 4-1 exhaust, stainless break lines, sprocket conversion, and jet kit with pod filters.
It's standing bare at the moment in my single car garage.
Initially, I was not planning on doing a total rebuild on the engine, however, I soon realized that i had a significant issue that needed to be addressed. I was originally planning on only removing the head and cylinder jugs to repair a nasty base gasket leak on the back side of the engine around cylinder 3/4. It did run great, with compression over all was good with cylinder 4 being slightly lower.
After removing the cylinders and cleaning up around the leak area i noticed some fine cracks along the webbing between cylinders 3 and 4.
The cracks spiderwebbed all the way down and there was noticeable movement. Additionally, when i was removing the sump and the strainer I found some fine metal shavings. The source of which was from a bolt of the incorrect length in the clutch cover that was rubbing and shearing on the clutch hub. (PO had the basket welded and I'm assuming that reassembly didn't go quit right.)
After consulting with a few friends and a great shop out my way, I determined that the only thing to do was to get new cases.
Many people would probably scrapped the project at this point and ebay'd/listed a part out, but I was always a bit more heard headed than most...not to mention I LOVE to see these gorgeous bikes out on the road.
Anywho, thanks to Fred over at Sky Cycles I was able to acquire a solid and clean set of cases which i further power washed/ brushed/ sanded as I am planning to bring the engine back to its OEM black glory upon reassembly.
I really enjoy doing these things by hand however sometimes i wish i had some better tools/equipment to really take the job to the next level. However, I'm happy with the outcome so far.
Currently, I'm awaiting some miscellaneous parts to continue on.
Things I've finished are:
1. Honed cylinders. Cleaned up nicely with good 45 degree crosshatching.
2. Pistons: Good shape, and cleaned up nicely, with new rings installed.
3. Lower and Upper Crankcase components installed including new cam chain:
Just waiting on new crank shaft oil seal, OEM O-rings, and gearbox plugs, then I should be ready to seal it up.
Things still on the list:
1. Going to be tackling the head next couple of days. Supposedly it had a valve adjustment done shortly before purchase, however i want to check guides, change seals, check retainers/springs/lap valves/etc... while I'm in there.
2. Rebuild clutch. The springs on the old hub were shimmed to prevent clutch rattle, then welded for strength. However, couple shims have some play and I've got a HD APE clutch kit so I think I'll be purchasing a new (used) hub to rebuild to go with the kit.
3. Reassembly and Paint.
WISH LIST:
1.GSXR suspension conversion.
I really envy some of you guys...A quick pick of my cluttered "work station," in my single car (or as the case may be duo bike) garage, located on the top of my portable table saw. And you might even be able to spot the every reliable and handy milk crates which are great stands and parts catches
.I'll fill ya'll in on the rest of the project as it continues.
Just wanted to give a quick thanks to all of you on the site. I don't ever really post and only recently joined as a member on GSR, however I've been reading as an anonymous guest for quite some time and am thankful for all the knowledgeable and helpful people here on the forums!
Cheers and wish me luck.
Nic
Comment