Finding and Fixing a Scraping sound....

[Guest]

1982 gs1100 ~ shaft driven

alrighty, so a few weeks ago my bike severely overheated. i have changed all the fluids and cleaned it up as much as possible.

Unfortunately, when i got the bike back on the road, there was a horrible scraping sound coming from the gearbox area.

the sound was constantly matching my speed, if i go slow, it scrapes slow, if i go 30, it sounds like a freakin' grinder.

needless to say i am not riding or even starting the bike until i get this resolved.

i was first told it may be the starter clutch going bad so i started workin towards that, recently i have been informed that my symptoms dont match a bad starter clutch, and rather some issue with the gearbox.

i took the oil cap off above the box (the SAE90 one). peek in, and see a TON of grainy sludge'y lookin' orange stuff. i also notice after some more inspecting that there is a leak of the SAE90 oil coming from the bottom of the engine (haven't pinpointed it yet)

i'm hoping that the box just needs a good cleaning, new oil, and somehow fix the leak...

heres my issue tho, how do i got about doing this? i have taken the side cover off and see a round rubber like plug attached by 4 bolts, can i take this off and clean it that way? or is there a better way to do it? tomorrow when i get off work I'll post some more detailed pics.

and secondly, if anyone knows where my leak MIGHT be coming from, maybe through experience or another thread, i would be very appreciative for that info, im hoping its just a gasket that needs replaced or better yet a bolt that needs tightened down. im really prayin' its not a crack somewhere.

thanks in advance!
Sincerely,
~Nate

[7981GS]

You might want to check this thread out: http://www.thegsresources.com/_forum...ty+Feet&page=2

Daniel

[Steve]

Sorry to bring you bad news, but your box will need a good cleaning and new oil.

But only after installing new gears.

Your bearings are shot, there is likely nothing you can do, except change the whole gear set.

It was "fun" to do on an 850, I hear the 1100 is even "funner".

.

[Bustedknuckles]

Nooo!!!!

so the only way i will be able to replace the whole gear set is to pull the engine off the frame correct?

is there no way to just open up the gear box and swap out the gears?

and do you think that a really good cleaning and new oil would do the job? or are you sure the bearings are shot?

if i have to pull the engine out and spend hundreds on the gears and countless days on the work im just going to scrap the bike.

[7981GS]

No.
I showed the replacement assembly in that link. Did you read it and check out the pic's?
I was able to gently pry the assembly out.
Keep track of the spacer shims.
You should be able to find an assembly either from a member here or on Ebay for a bunch less than the cost of new parts.
I got the seal and nut from the dealership for spares.

Daniel

[Bustedknuckles]

gotcha

yea i read through the whole thread, im amazed you were able to keep that thing up.

fortunately mine didnt lock up just screeching like a, well... like a busted gearbox...

im lookin on my work computer right now and it doesnt load most images so i will have to check it out when i get home.

i will be skulking around ebay and the "for sale" section of the GSResources for a new assembly.

im going to do a little more research and hopefully find a DIY or guide on replacing it. as long as i can get a little guidance i will replace it myself. otherwise i just secondguess and question myself at every turn. im always too nervous to mess something else up due to an improper installation.

thanks again 7981GS,

your input has put me more at ease that this fix wont be the end of my bike... if you have any more knowledge you could drop on me i would be very appreciative.

Sincerely,
~Nate

[SqDancerLynn1]

terminology differences !!! The 850 has a transmission It also has a beveled gear set- secondary gear set !!! two different assemblies !! 90 wt oil leak! YOUR problem is in the secondary gear set it can be replaced without removing the motor. You will need to remove the swing arm.

Not sure if a GS1000 set will workin your 1100. I do know the 850 secondary will not fit !

[Bustedknuckles]

okay

well i do love your enthusiasm,

you will have to excuse me i AM somewhat of a novice on the finer workings of engines and the mechanical gremlins that occur in them. which is why i even get on this forum, for guidance and advice.

so i have done more research in the right direction (thanks to you) and believe i finally found what i need. below is an image of the expanded diagram and the next post will be an image of the actual part (to be sure). as soon as i hear back from you to confirm i will be ordering it.

Lastly do you think i will also need to replace the gears that travel through the swing arm or is this something i will only know once i take it apart and peek at it?

here is also a link to a gear assembly for sale online, is this way more than i need?

http://cgi.ebay.com/ebaymotors/82-Suzuki-GS1100GL-GS1100-Transmission-Gears-Assembly-_W0QQcmdZViewItemQQhashZitem3cae83b5c9QQitemZ260625905097QQptZMotorcyclesQ5fPartsQ5fAccessories

Thanks in advance,
Sincerely,
~Nate

[Bustedknuckles]

hopefully...

i hope this is all i may need but i feel that is very optimistic...

http://cgi.ebay.com/ebaymotors/GS1100-GS1000-GS-1100-1000-SECONDARY-DRIVE-GEAR-78-1981-/280555822251

again thank you for your knowledge...

[Steve]

i hope this is all i may need but i feel that is very optimistic...

http://cgi.ebay.com/ebaymotors/GS1100-GS1000-GS-1100-1000-SECONDARY-DRIVE-GEAR-78-1981-/280555822251

again thank you for your knowledge...

That's one of them, but you should really get the other part of the assembly, too.

.

[GSexpress]

That is most likely the part you need. You won't know for sure till you get it out. It is the bearings in that assembly that are most likely shot causing your noise. But it could be the other gear that it mates with and goes out to the drive shaft. It is a similar assembly with the same kind of bearings. You'll have to pull one and check it. Even if it's bad you'll still have to make sure the other one os OK. Ideally it is best to change these gears as a set, but not an absolute. If the bearings are still good in the output gear and there is no damage to the teeth, you can get away with just changing the one driving gear, You will have to be very maticulas in cleaning out the housing to make sure you get any metal debris and old oil out of it. It will also be neccessary to change the gear oil with in a couple of hundred miles, and then change it again 500 mi after that checking to make sure it comes out clean. If it doesn't ( has metalic content ) the other bearing set may need changing as well. If it cleans up and the noise is gone you're good to go. It should be 80% as good as changing both. But changing both is the only way to be sure all is good and that it will last another 100K miles or so.

i hope this is all i may need but i feel that is very optimistic...

http://cgi.ebay.com/ebaymotors/GS1100-GS1000-GS-1100-1000-SECONDARY-DRIVE-GEAR-78-1981-/280555822251

again thank you for your knowledge...

[Bustedknuckles]

thank you!

thank you guys so much, i just needed some input from you GS veterans before i continued. i will be ordering BOTH gear sets just to make sure, then i will be pulling the arm and replacing, flushing, and cleaning everything.

Thanks again fellas'
Sincerely,
~Nate

[GSexpress]

If you go with a new set of gears there will be some additional setup. The existing spacers will probably not center the new gears perfectly. The manual shows the procedure for getting the proper gear spacing by checking the mating pettern. This may require new/different spacers. Also don't forget to get new "O" rings. There is also another alternative to all new gears and that is just replacing the bearings in the assemblies. It's cheaper if you buy them from an automotive bearing supply. They have to be pressed off and on the gear though, and some machine shops may want too much for that to really save alot over buying the assemblies. But if you can do it yourself, or have a friend that can, it'll save you some dough.