Big mess up on GS1000 engine install. What are my options?

[crackerman]

I'm going to see it I can take the whole engine to a welder and see what he can do. I'll do as Rusty says and tap the hole closed from the inside. Here's a shot of the engine bolts. As you can see there's not too much different in length but make a huge difference in what side they go on. The smaller one actually seemed work fine on the right side.

Top one, right side, bottom bolt, left side.

[rustybronco]

I'm thinking they can stick an electrode through the bolt hole and have an assistant flip the switch on the welder. You could also remove a portion of the case above the hole, TIG the hole shut and weld the section back in place. But who am I to say what they will think may be the best way to attack the problem.

[crackerman]

So I'm at this point with the engine:

Didn't want to split the case but I'm glad that I did. Found this piece in the center that was broken into pieces:


The original hole that I made actually got bigger and the piece popped out. Took the bottom case to the welder today and sounds like he'll be able to fix it.

Question. What have you guys used for sealant when putting the cases back together? Book says (Suzuki three bond; 99000-3 1030)?

[Kiwi Canuck]

My Suzuki dealer sold me Three Bond 1194, that's what they recommend.

Worked great, but it can get messy, you need to get an even coat on all the mating surfaces.

[blowerbike]

did you notice that your cam chain (crank sprocket) guide is broken?
if so disregard this post

[FLHGSRay]

This seems to happen alot when engine guards are removed. The bolts that hold the guards are longer than the stock bolts. I actually read in a thread here about it as I was bringing my bike back from the dead. I ended up buying longer bolts and cutting them to the proper length.

[blowerbike]

going off of memory this happens to 1000's with stock bolts.
one side is longer than the other...mix them up and POP...right through the engine case.

[Flyboy]

For sealing the cases, I use Indian Head, have for years and swear by the stuff, I use it on all the Alfa Romeo engines I have built, and they take no gaskets, all machined fit, narry a leak, ever.


Or failing that a good red RTV will do the job.
No need to pay Suzuki prices for essentially the same stuff under brand name,

[JTGS850GL]

Sorry this happened to you but I do thank you for the heads up on this. I would have never thought that mixing up the bolts would cause such a horrific problem. Getting ready to do an engine swap on my GS1000 and I could see this happening to me. Hope everything goes well and thanks again.

Julius

[crackerman]

Back to square one. Got the engine welded and put her back together today. I'm a little worried about the the transmission. The gears are like a rubix cube and I figured out how to get the top mated with the the bottom, but I'm not sure the shifting will work right now. I'm guessing I can install the clutch lever and do a dry shift through the gears? I'd hate to drop 4 quarts of oil in the engine then find out I gotta split the cases again.

Any one know if I can do a dry testing of the transmission or the best way to test?

Anyway she's back in the bike. All bolted up, making sure not to put the bolts through the engine case. I think I've mastered installing the engine on my own.

[rustybronco]

Bar the engine over using a 19 mm wrench on the right side under the points cover all the while pushing the shift lever. You should be able to feel it go into every gear on the way up and the same on the way back down.

[TeamDar]

Bar the engine over using a 19 mm wrench on the right side under the points cover all the while pushing the shift lever. You should be able to feel it go into every gear on the way up and the same on the way back down.

Much easier to turn the rear wheel by hand on the center stand. That way you are just moving the transmission gears and not the crankshaft and clutch. If you don't have the chain installed then just turn the countershaft/sprocket.

[crackerman]

Got the chain on and the shifter. Shifted down, but now seems locked up. Can't spin the wheel or move it into neutral. Going to try rolling it of the bike stand. Not feeling good about this.

[TeamDar]

You can't move the wheel either direction?

[crackerman]

You can't move the wheel either direction?

Yea the wheel will move about an inch in each direction. Shifting doesn't seem to make any difference. I've been looking at the service manual and I think I know what I need to do. The black and white pics are pretty terrible so it's kinda hard to see how I'm suppose to install. I found a guy selling a mostly complete gs1000 for $300. I might just swap the engines and put my top end on.

Back to pulling the engine and the tear down. I've done this so many times now it should only take me a couple hours.