Looky what folowed me home.

[Nessism]

I'm getting old and lazy. Paint stripper on an engine like that will be a LOT of work. Messy as all heck and you have the danger of blasting water in past the various seals and gaskets if you use a pressure washer (not sure you can get good results without it though). Wear eye protection and coveralls. GOOD LUCK!

[JTGS850GL]

That's pretty much how I do it though using what we call paint stripper (the professional, old fashioned stuff that burns your skin) which I presume is the same as your aircraft stripper.

Yep, the same product with a different name. I like using the Aircraft Stripper in a rattle can. Gets in there good and you don't need a brush.

I'm getting old and lazy. Paint stripper on an engine like that will be a LOT of work. Messy as all heck and you have the danger of blasting water in past the various seals and gaskets if you use a pressure washer (not sure you can get good results without it though). Wear eye protection and coveralls. GOOD LUCK!

I may just start on the less obvious areas and see how it goes from there. It would be a shame to not clean it up while it's not in a frame. I sure don't want to take apart a perfectly good engine just to clean it up if I don't have to. Good point on using skin and eye protection.

[JTGS850GL]

One little set back discovered. Seems the stator is toast. Ohmed out each leg and it looked OK but then I checked each let to ground and found each leg reading 24K ohms. Oh well.... Kind of expected it since it looked like the bullet connectors were burnt and one was missing. The three wires were all yellow so it seems like the stator has been replaced once before. So I guess I'm in the market for a new stator. I checked to see if my good stator in the 1000 engine would work but Suzi shows a different part number between the 1980 1000G and the 1983 1100G motors. Shame if they're not interchangeable since the 1000G stator is almost new.

[JTGS850GL]

OK, today was the day to get things spruced up. Here's what were the tasks for the day:

Sand and polish all covers.

Gap and install new plugs.

Install valve cover with new cap screws.

Replace burnt stator with stator from GS1000G Frankenstein engine.

Transfer GS1000G ignition from Frankenstein engine to GS1100G engine.

Transfer oil pressure sender from Frankenstein. Found this damaged sender by accident. Just decided to check it and it was bad.

Replace oil filter and oil.

File and polish head fins.

Replace intake O-rings and mounting screws.

Here are the results:








I know that the decals are not correct, but they do match the color theme I'm going for. I'm doing a red/black/gold theme with chrome/Polished aluminum as accent. The plan is to install this engine in the 1000G in my signature.

Next step is to decide if I want to try to fire up the engine before the install or after. I have an extra set of carbs that I'm going to setup for the 1100G engine before hand. I also have a GS1000 frame (minus engine) that I can use as a test bed. Any opinions on what direction I should go in? I have no direct experience with this engine and I'm a little gun shy based on the original 1000G engine turning out to be toast because of a seized rod. I did do a compression check on the 1100G engine and all cylinders came out to be between 142 and 148 cold. Should I try to fire her up before the install in order to verify everything or should I just install the engine and test it then. Right now the 1000G is in running condition so I would hate to find out that the engine has issues after the install.

Any input would be greatly appreciated.

[JTGS850GL]

Any suggestions on how to test the new engine?

[Nessism]

Slam it in. No need to test. There is need to adjust the valves though. I wouldn't even attempt to run it without doing that first.

[eil]

I would think it would be even more work to get a test setup going off the bike than it would be to just throw it in and fire it up. Turns over freely by hand, yeah?

[Charlie G]

This sure tarted up nicely!

[JTGS850GL]

Slam it in. No need to test. There is need to adjust the valves though. I wouldn't even attempt to run it without doing that first.

Actually I've already adjusted the valves and then did the compression test afterwards. On top of that I've drained the oil and replaced the oil filter. There was a distinct smell of gas in the original oil so I filled and drained it again after I did the compression test. As reported above, the compression test yielded a 142-148 range between the cylinders.

The main reason I was asking about testing the motor before hand was to minimize my down time of the GS1000. I'm going to have to do the replacement by myself, unassisted, so I'm thinking it will take a little while to pull the original motor and put this one in. That's assuming that there's no one local that would be willing to give me a hand. Just didn't want to run into problems afterwards. So I guess it's bite the bullet and begin the removal of the current engine.

[JTGS850GL]

Doing some preparation in advance to the engine transplant. Decided to pickup a tool that should come in handy:





Harbor Freight was running a sale and I had an old gift card laying around so with the sale price of $79 minus the $20 gift card it came in at under $65 with tax. Figure I can use it to remove and reinstall the generator in my motor home and probably will come in handy for several other tasks. It can lift up to 1500 lbs so should work out pretty well.

[Baatfam]

Those lifts are very handy for removing/installing the motor in these bikes....

[JTGS850GL]

I planned to use a piece of plywood to bridge the lift with the frame and simply slide the old engine out and the new engine in while the bike sits on it's center stand.

Just to make sure that everything is in good working order, I tested the gear position sensor and found it to be rather high in resistance. The resistance seemed to vary from 12 ohms to 300+ ohms so it pulled the sensor and sanded it down to clean the contacts. After that it measured no more then 6 ohms in any gear and neutral.

Next thing I want to do is verify that the ignition pickup I transferred from my 1980 GS1000GL Frankenstein engine is in good working order.

[JTGS850GL]

A little progress today on the 1100G transplant. Here's where it sits today:



1000G engine out and 1100G engine ready for install. Total time from start to now was right at 2 hours.
That included test fitting the new V&H 1100E exhaust to the 1000G engine:


This is what I'm most concerned about on the reinstall.
Any suggestions on the best way to get that darn driveshaft and boot connected without tearing the boot up?
Planning on buying a new boot before the engine install. The old one is a little hard and I can see some cracking.


It does give me an opportunity to get things cleaned up on the frame before the install. Lots of dirt and silver overspray:


Planning replacing the following while I'm at this stage:

Driveshaft boot
Drive shaft clamp
Drive shaft boot spring
Clutch cable

Any other suggestions on what should be replaced?

[Higgibaby]

When I removed and reinstalled my motor I was down to the frame, I just laid the motor on its side (with no fluids in mind you) laid the frame over it and attached the engine mounts and propped it up. Took about 10 mins in all

[JTGS850GL]

Frame now repainted and ready to accept the motor.






I'm going to attempt to slide the motor in with the rear swing arm still attached. If it proves to be too much of a PITA I can always pull it then. Here's how she looks now.


G&S Suzuki told me that they shipped my parts today so I should be able to get the engine in within the next week or so.

I'm converting the choke to the newer 82+ style lever choke.


Now need to figure how I'm going to plug up the hole where the old pull choke was. Any Suggestions?


In the process I found that the 9 wire connector that went to the left hand controls was melted together.




The Frankenstein bike made another donation today and now everything is in good working order. Changed out the handlebars to a chrome set that Chef contributed. A little better sitting position. The old set had me laying too far forward for my liking.