'82 1100E Top End Rebuild

[Guest]

Thanks for welcoming me to this forum. I have a little wrenching experience on vintage Japanese motorcycles and always need cash so I agreed to do some repairs for the owner of an '82 1100E. It's the 16 valve engine. I'm having a really difficult time finding a downloadable manual for it.
The guy who was riding the bike apparently kept spraying starter fluid in the #1 cylinder to start it and blew the head gasket. Oil was leaking out of the head under the #1 exhaust pipe.
I will def post some pics if I can. I had to cut the head off a couple of exhaust bolts to get the exhaust off. Took it to a shop to get the bolts extracted and chase the threads on a couple of spark plug holes.
I'm hoping you all can help me out with some Suzuki GS tips and maybe even some specs as I put her back together.
Thanks again!
HoganJr

[Nessism]

I'm having a really difficult time finding a downloadable manual for it.

HoganJr

Got me a chuckle out of this. You obviously haven't searched once you found the forum because if you had, you would find literally hundreds of reference to this website...http://members.dslextreme.com/users/bikecliff/

[posplayr]

Got me a chuckle out of this. You obviously haven't searched once you found the forum because if you had, you would find literally hundreds of reference to this website...http://members.dslextreme.com/users/bikecliff/

Many times the hardest thing to know is what you don't know. Now if you are not even looking well..........

[hoganjr]

thanks for the link. I found the manual I need.

HoganJr

[hoganjr]

I got my top end kit today and borrowed a valve spring compressor from a friend. But the tool is not gonna work. I think I know what I need...one of those "C-clamp-kinda" tools. I'd love to hear from somebody who has removed and replaced springs on one of these motors. Is there a specific tool I need or can I get a universal tool that will work?

Thanks.

HoganJr

[stetracer]

your gonna need one like this

http://store.schnitzracing.com/schnitz-valve-spring-compressor-kit/

[eil]

I have heard of people using a large C-clamp from Harbor Freight plus an oxygen sensor socket (or just cut your own slit into an old deep-well socket) as a poor-man's spring compressor. Haven't tried this myself, but it's on my todo list.

Also, some auto parts stores will rent you a spring compressor.

Also, if the engine will be apart for some time and you just want to get the valves free for now and worry about assembly later, I have seen people put a deep well socket over the retainers and bang it with a mallet to get the retainers free. (This is more risky though, as if you're not careful you can lose them little buggers very easily.)

[Arronduke]

I have heard of people using a large C-clamp from Harbor Freight plus an oxygen sensor socket (or just cut your own slit into an old deep-well socket) as a poor-man's spring compressor. Haven't tried this myself, but it's on my todo list.

Also, some auto parts stores will rent you a spring compressor.

Also, if the engine will be apart for some time and you just want to get the valves free for now and worry about assembly later, I have seen people put a deep well socket over the retainers and bang it with a mallet to get the retainers free. (This is more risky though, as if you're not careful you can lose them little buggers very easily.)

I use the socket and mullet option, with the addition of a small magnet in the socket.... No losing them little buggers.

[hoganjr]

reinstalling the head!

this has been a real education for me. I did the valves on my GL1000 a couple years ago and don't remember struggling with it. I rented a valve spring compressor from the auto parts store and it doesn't work without some kind of adaptor.
I pulled apart the tool my buddy loaned me. The one that looks like a gear or pulley puller. I lay a little bar across the "fork" part of that tool and push down. My wife sticks the magnet in there and pulls out the keepers. To put them back together I push down again and she guides the keepers back into place. Works pretty good and it's a great ab workout.
I'm ready to reinstall this head.
Any tips or tricks or pitfalls to avoid in installing the head gasket...camshafts...timing gears...
Clearly I need a little help!

HoganJr

[hoganjr]

mostly finished

having a little trouble getting the owner to come up with the cash he committed to pay me for this job so it is still in my garage. I started it and adjusted the idle and ran it a couple of miles the day I finished it (a couple of weeks ago). It seems to run ok except it races up pretty high when I turn up the idle to where it probably should be and will die sometimes after a few minutes if I back the idle off to where it won't surge. Nothing that a carb sync probably wouldn't cure, except that he is running individual pods on the intakes and one of the carb-to-head boots is all buggered up on the carb end. The owner hasn't agreed to pay me back for a new one and I'm thinking it is pointlless to try to tune the bike with a leaking boot.
Maybe, just for my own prides sake in doing a good job I should buy the boot, install it, sync the carbs and make it run right.
My question: is there a cheap, DIY-kinda fix or replacement for a boot with a buggered up end?
This bike is really too nice to be going down the road like this.

hoganJr

[blowerbike]

just buy a good used boot...buggered??? i don't get what you mean.

[hoganjr]

the rubber is split and coming apart across the groove where the clamp goes on the carb end. The parts store where I deal says they have no used boots for sale. I thought maybe this was a common thing and some of you GS guys had developed a cheap and easy fix.

HoganJr

[eil]

Yes, it is a common thing. The cheap and easy fix is to buy a new boot. The correct and easy fix is to buy four new boots. Thankfully the intake boots on these engines are not as expensive as the 8-valve ones.

[blowerbike]

the rubber is split and coming apart across the groove where the clamp goes on the carb end. The parts store where I deal says they have no used boots for sale. I thought maybe this was a common thing and some of you GS guys had developed a cheap and easy fix.

HoganJr

i have MANY GS1100/1150 parts...i'm just east of richmond In.

[blowerbike]

oh,
and if a person uses automotive type clamps....they will cut the boot's every time.