1983 GS1100ES Engine Rebuild.

[bellucci]

Great job... sounds perfect... break it in the right way and have fun...
Curt

[niclpnut]

Hopefully the Carbtune will arrive tomorrow. Any throttle over 2500k rpm and it begins to bog down.

Nic

[niclpnut]

Carbtune came today. Didn't have much time to play with it. Really just installed the restrictors, hooked it up to the bike and began to make some adjustments to the mixture screw.



Seems like I can get it fairly close to balancing, but I'm still hitting a brick wall when I throttle up to 3-4k, at which time it begins to bog. Idol is great, even before starting to sync. And everything is set as specified by the jet kit.

As the bike got fully warmed up, It began to smoke some out of the breather hose. (do have a filter attached to the hose)

I'm assuming the blowby is normal since the rings haven't had a chance to seat yet.


Generally how long should I expect to see it smoke?

I'm confident that the rings were installed correctly. I accounted for proper spacing of the ring gaps and watched every ring go into the bore as my WIFE lowered her jugs, errrrrrrr, THE jugs over the pistons.

I'm assuming a compression test to double check would be irrelevant as the rings haven't begun to seat.


Long work day tomorrow, but might be able to mess around with things over my break.

Nic

[Nicholaschase29]

Carbtune came today. Didn't have much time to play with it. Really just installed the restrictors, hooked it up to the bike and began to make some adjustments to the mixture screw.



Seems like I can get it fairly close to balancing, but I'm still hitting a brick wall when I throttle up to 3-4k, at which time it begins to bog. Idol is great, even before starting to sync. And everything is set as specified by the jet kit.

As the bike got fully warmed up, It began to smoke some out of the breather hose. (do have a filter attached to the hose)

I'm assuming the blowby is normal since the rings haven't had a chance to seat yet.


Generally how long should I expect to see it smoke?

I'm confident that the rings were installed correctly. I accounted for proper spacing of the ring gaps and watched every ring go into the bore as my WIFE lowered her jugs, errrrrrrr, THE jugs over the pistons.

I'm assuming a compression test to double check would be irrelevant as the rings haven't begun to seat.


Long work day tomorrow, but might be able to mess around with things over my break.

Nic

You will always have smoke coming out of the valve cover breather vent.

When you sync the carbs, sync them at idle. When the butterflies are open the small variance should be less significant.. IMO.

[rapidray]

If you sync the carbs with the idle turned up between 1700-2000 rpm, the bike will run smoother when you are riding it. Ray.

[niclpnut]

Looks like the needle valve O-rings tore. No wonder it wouldn't throttle up. Was flooding with fuel.




Another set on order, and will try it again with some more grease.

Nic

[UncleMike]

Read through your thread this afternoon and will be following with interest from now on. Looks like you're doing a great job, and gives me a lot of confidence for when it's time to freshen up the 1150.

[niclpnut]

Well, I finally got the clutch and some miscellaneous electrical issues sorted out, and was finally able to take it out for a spin! After a quick check with the Carbtune, I put the tank, seat, and front fairing on.



Rode for a little under 20 miles, and it sure felt good to finally have it out of the garage!

Pulls nice and tight, a little stumble around 3k, and a plug chop tells me it's running lean.


I'll make some more adjustments tomorrow. Just happy everything seems to be going in the right direction.

Still more work to do. Electrical, fixing broken tabs on side cover, new windscreen, mirrors, grips, rear brake light switch, some more touch up paint.......

The list never seems to end but thanks to all the help here, it eventually gets a little shorter


Thanks,

Nic

[niclpnut]

83 1100 ES clutch install:

first is washer against bearings:



Next is oil pump drive gear and bearing:




Then the clutch hub and bearings, get the hub lined up then seat the bearings:




Next is the clutch hub spacer and slotted washer, with the slots facing in:



Then the hub itself and the fibers/plates. 10 fibers and 11 plates in stock clutch. First plate is behind piano wire. Alternate fibers and plates.




Lock washer next, and hub nut. Torque to manual specs. I used a c-clamp to hold the inner hub:



fold the lock washer over to secure the hub nut. Set pressure plate into position, and tighten spring bolts. I torqued to right about 6lb/ft:




Buttoned up the cover, making sure the knotches on the pressure plate bar are facing to the left and line up with the cover.

Reatached the clutch cover arm, at 90 degree to the case, and have about 2mm of slack at the handle.




Nic
__________________

[blowerbike]

DOES IT WORK FINALLY?????????
PLEASE TELL US ALL

[niclpnut]

Yep, the bitch is alive.

The plates/fibers were just sticking together and not releasing. just needed to get them loose, and now it works great.


Going to be 60+ degrees tomorrow! and I'll actually have a bike to ride!

Thanks,

Nic

[whereiwannabe]

Wow, this was a fantastic thread to follow Nic. Great job on the pics and verbiage. A real keeper!

[Suzuki mad]

I know its an old thread of a GS(X)1100ESD rebuild. Just wanted to ask a question really. Did you change the cam follower on the exhaust camshaft lobe that was scored?

[niclpnut]

The rocker pad was in good shape, no high spots, grooving or marks of any kind. I didn't change it out, and have checked the new cams several times since the rebuild for wear and there is no evidence of any.

[Nincompoop]

Great job on the rebuild niclpnut!! Sorry if i missed it, but was the crack in the engine case the cause of your whining problem?