A little repair on my 82 1100L

[Chris Hagen]

Started out replacing some of the 20 year old rubber on my bike and I have ended up doing a bit more .

1.) Checked the valves. 26K miles and 29 years later and they were perfect .
2.) Took off the Final drive and oil drained out of my swingarm .
3.) Found the wine in the transmission when the drive shaft came out with the swing arm. Threads broke off the secondary drive.
4.) Ordered new secondary drive gears and bearings $327 after taxes. See Number 3 .
5.) New u-joint boot.
6.) New Intake boots (both sides)
7.) Installing a Handlebar riser to play with Handlebar position http://www.advdesigns.net/roxanhari21r1.html
8.) A few other odds and ends.

Will post some pics when I am done.

[azr]

Ya that sounds like a typical rubber replacement.........

[Charlie G]

I'd be interested to more about this transmission whine and gears you replaced.

cg

[Chris Hagen]

This has been one problem after the other, hopeful for the final outcome.

Lets start with Carbs.
I have had these "professionally cleaned" three times as I did not have the dipping chemicals. I cleaned them myself this time.
The bad.
1.) These carbs have never been separated.
2.) All O-rings in the carbs were rock hard.
3.) Fuel overflow t's were completely loose.
4.) Two idle jet plugs crumbled when taken apart.
5.) One Completely stuck float valve.
6.) One Air jet o-ring was missing.
7.) Half the bolts were stripped (had to use a pliers on 5 of them)
8.) Carbs were basically filthy, inside and out.
9.) Suzuki doesn't even have the correct parts linked into their system (what was available for these carbs at least.)
10.) Not cab but the intake boots were hard and cracking, as well the o-ring was completely rock hard with obvious leaking.

The Good.
1.) New float gaskets
2.) All new O-ring kit from Robert A. Barr (I should get these today and will let you know if they are worth what he says) $15.
3.) Fully dipped, carbs dipped for over an hour each and then cleaned. these babies are clean now
4.) Picked up new stainless steel bolts for the entire carb set, Allen heads for the brace bolts.
5.) New plugs for the idle jets, new float valve to replace the bad valve.
6.) Cleaned out the half plugged Idle Jet from carb 2.
7.) Should be put together tomorrow .
8.) New carb boots and o-rings with new stainless steel allen head bolts.
9.) New air box boots as the originals would not even bend anymore.

[Chris Hagen]

Now lets talk the drive line.

Secondary gear.
The Bad
1.) Shims -> Discontinued.
2.)Inner Bearring -> Discontinued, however, still available through bearing companies . Thanks to Bearings and Drives in Fargo, ND for finding this.
3.) The darn thing was broke in the first place.
4.) After putting it back together gears would barely move and slipped a ton (needed more shims , check number 1.).

The Good.
1.) Dealer charged me $25 labor to rebuild the secondary drive (I had already purchased all new bearings and the new seal.) I don't have all the tools to accomplish this.
2.) Larson Welding in Fargo, ND has shim stock which I can fabricate new shims to fill in the extra .011 inch gap that is needed for proper alignment. Just the right amount of play and can barely hear the gears contact each other .
3.) I should have the secondary drive back together tonight.

SwingArm.
All good here.
1.) New Swing Arm boot and coil retaining spring.
2.) It was out, perfect time for some fresh black paint .
3.) Bearings were still perfect after 29 years.

Final Drive.
All good here as well.
1.) No apparent leaks.
2.) Still wonderfully tight.
3.) Nice and clean now .

Etc.
Valve cover all cleaned and ready to install.
new gaskets for this, the timeing cover and the Cam chain tensioner that was leaking.

[Chris Hagen]

I purchased a Carb Sync tool to sync the carbs with on my bike so I should finally have a clean power curve .

Hoping the bike runs better with the carbs 100% functional instead of 70% functional, I will find out on Friday I hope.

I have the bike apart still and will take some pictures of the whole thing before I start assembling it again.

One suggestion for everyone. Sam's club has a wire cart.

http://www.samsclub.com/sams/shop/product.jsp?productId=141872&navAction=

This was a wonderful addition to the project, moved my workstation with me .

Should finally have all my parts today and can assemble this beast again this week.

I will keep everyone posted.

[fishfarm]

Now lets talk the drive line.

Final Drive.
All good here as well.
1.) No apparent leaks.
2.) Still wonderfully tight.
3.) Nice and clean now .

You didn't mention removing and inspecting the rear wheel hub spline. It's a common failure on some of our 82's. Mine has the softer gold-colored spline and was showing some wear at my last tire change. I have a new silver one on the shelf for the next time the rear wheel comes off. See this:

http://www.thegsresources.com/_forum/showthread.php?t=149097&highlight=check+splines

[Chris Hagen]

Good call. I will be taking a look at that.