Engine Timing

[sallison20]

I've got a 1982 GS 1100 G that I just got done putting back together. My question is that in the manual I see that the timing on the cams should be 20 links between the exahust cam at the number 2 mark and the intake cam number 3 mark. My question is what is the correct position on the pistons? Does piston number one need to be all the way up or down or all pistons even across? I would thing pistion number 1 should be all the way up and then the timing chain with the timing listed above with the number 1 mark on the exhaust cam pointed towards the cam gasket seal. Any help would be welcome.

Thanks.

[hikermikem]

Remove the sig-gen cover & rotate the crank until the 1/4 "T" mark is aligned with the timing mark. Be careful not to let the timing chain bunch up around the crank... hold it up as you rotate the crank.

Then position the exhaust cam with the #1 arrow even with the top of the cylinder head. The #2 arrow will be pointing up & that's where you start counting the pins on the timing chain towards the intake cam.

Don't forget to engage the cam chain tensioner before you rotate the crank around several times to make sure you got it right.

Check, double check, and triple check that the timing chain is fitted correctly, it's easy to be one tooth off & it won't run right if it is...

Mike

[sallison20]

Thanks, I'll give that a try this weekend.

[Nessism]

Did you tear apart the top half of the engine without looking at a service manual?

[sallison20]

The service manual i have is fairly vague on timing. It showed the 20 link count between marks 2 and 3 on the cams, but nothing about the crank. That's what i get for trying to hurry.

[sallison20]

and not having all the necessary information.

[Nessism]

If you go to Basscliff's website you can download a factory Suzuki service manual for free. I don't think he has an 1100G specific manual, but the top end cam timing is the same for the 1000 and 1100.

http://members.dslextreme.com/users/bikecliff/

[sallison20]

Thanks again. I've got the timing taken care of, but now for some reason I can't get any fuel to the carbs. I tried to start the bike, but it would never even try to fire. Then I got my 10mm wrench and loosened the drain bolt on the number one carb only to find it dry. I checked the lines from the tank and all good, drained the tank all good, took out the pet cock and all good. Now I'm stumped again.

[Nessism]

Did you try the Prime setting on the petcock to fill the float bowls?

[sallison20]

Yes, i first used the normal fuel setting, then i tried the prime (which i believe is the full flow setting) then i tried the res. Still nothing. I'm thinking I need to try using an external fuel source so that I can remove the pet cock and tank from the equation and see if i can get fuel into at least one of the bowls or get enough fuel so that it comes out the carb overflow tubes. then i'll know if i have fuel in the carbs or not.

[Nessism]

Pull the fuel line off the petcock.

Slip on a length of free tubing, aimed at a gas can.

Turn petcock to Prime position and observe flow. Fuel should freely flow with the petcock in Prime and fuel should stop with petcock set to On or Res, unless vacuum is pulling on the petcocks vacuum line port.

Pretty simple when you think about it.

Check for free flow from your petcock and assuming it's working as designed, set it to Prime for a few min. and then check for fuel in the float bowls.

If the petcock is flowing, yet you get no fuel in the float bowls, your float needles are stuck.

[sallison20]

That was the problem. The petcock is malfunctioning. I did as you stated and on Prime, nothing happens at all. I move it to On and then created the vacuum and fuel flowed. Needless to say, new one is on order.

One other question for you. I must not have something set quite right because when i'm on the highway running say 60 and mash the gas, it dogs out and hickups. if i go at it slowly it will run up as it should. Under normal riding all seems to be fine. idle is at 1300rpm, at 70mph tach shows about 4600.