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    #16
    Looks like maybe it's a stater clutch bolt. Maybe the starter clutch let go and caused all the damage... 🤔
    My Motorcycles:
    22 Kawasaki Z900 RS (Candy Tone Blue)
    22 BMW K1600GT (Probably been to a town near you)
    82 1100e Drag Bike (needs race engine)
    81 1100e Street Bike (with race engine)
    79 1000e (all original)
    82 850g (all original)
    80 KZ 650F (needs restored)

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      #17
      More bad luck. Sorry for all the hassle.
      Ed

      To measure is to know.

      Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

      Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

      Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

      KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

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        #18
        Ok, situation like that can happen. New engine? New block? Keep the pistons?
        Bonne chance
        1982 GS1100G- road bike
        1990 GSX750F-(1127cc '92 GSXR engine)
        1987 Honda CBR600F Hurricane

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          #19
          Just realize the 1100ED is arguably the pinicle of air cooled Superbikes. And exhaust baffles? We don't need no baffles!
          1982 GS1100E V&H "SS" exhaust, APE pods, 1150 oil cooler, 140 speedo, 99.3 rear wheel HP, black engine, '83 red

          2016 XL883L sigpic Two-tone blue and white. Almost 42 hp! Status: destroyed, now owned by the insurance company. The hole in my memory starts an hour before the accident and ends 24 hours after.

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            #20
            Yeah Norm, a starter clutch bolt was my first guess too. But there is no way that a starter clutch bolt can get into the #1 piston/crank cavity???? The odd thing is that this is the only part of the case broken. The top half looks like new on the inside. Here is a picture showing a wider view of the broken area:


            Now my question is......can I repair the broken area since it looks to not have any real pressure on it?

            All the rods (except #1 has a few nicks) and bearings look and feel great. No other damage anywhere in the crankcase that I can see.

            I am guessing that someone dropped a bolt into that #1 piston/crank cavity, ran it and the bolt bouncing around broke the cylinder sleeve and chewed up the piston skirt before breaking this area of the crankcase. Now since these crankcases are made of unobtainium, I guess a repair is in order, if possible.

            I have a stock set of pistons and cylinders headed to me now. My thinking is that the 1134 kit has such thin sleeve walls that it caused the sleeve to break easier than normal. (of course, the bolt is going to break something!)

            Sound plausible? Can it be repaired?

            Thanks!
            Ron
            When I die, just cremate me and put me in my GS tank. That way I can go through these carbs, one more time!https://www.thegsresources.com/_forum/core/images/smilies/cool.png
            1978 GS750E - November 2017 BOTM
            1978 GS1000C - May 2021 BOTM
            1982 GS1100E - April 2024 BOTM
            1999 Honda GL1500SE

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              #21
              There are windows in the cases underneath the main bearing. That is a starter clutch bolt. It is short because it broke. It is beat to *@%^$*@%^$*@%^$*@%^$ because it bounced around under the number one piston and rod after it found its way through the window.

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                #22
                Since that's an internal web my guess is you will be okay with that piece broke out. Oil will sling and fill up that cavity though which may be a bigger problem. One other option is shape a replacement piece and have it TIG'ed in place, then file it flat. I'd be inclined to go that route but since the aluminum has been in oil for 30+ years the welder may experience a lot of splatter.
                Ed

                To measure is to know.

                Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

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                  #23
                  My apologies Norm and TeamDar! After removing the crank I can see where the bolt could have gone through one of the two passages. Weird thing is that there is no scaring in the stator area and no missing bolts!

                  I guess someone could have picked up an extra bolt while the stator was off and it got magnetically held while they put it back together??? Who the #$%%& knows?

                  Yeah Nessism, I was thinking the same thing about the TIG welding. I wonder if a high-grade metal-filled epoxy would work?
                  Ron
                  When I die, just cremate me and put me in my GS tank. That way I can go through these carbs, one more time!https://www.thegsresources.com/_forum/core/images/smilies/cool.png
                  1978 GS750E - November 2017 BOTM
                  1978 GS1000C - May 2021 BOTM
                  1982 GS1100E - April 2024 BOTM
                  1999 Honda GL1500SE

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                    #24
                    Got a set of stock pistons today for the pig! Cylinders should be here on Friday. Ordered new rings from Cruzinimage.net. Have a bunch of gaskets to order from Parts Outlaw. Still have to find someone to do the TIG welding.

                    I might have this thing together by Halloween, ..........or Thanksgiving, ........... or Christmas! Ah heck, lets shoot for Brown County next year!
                    Ron
                    When I die, just cremate me and put me in my GS tank. That way I can go through these carbs, one more time!https://www.thegsresources.com/_forum/core/images/smilies/cool.png
                    1978 GS750E - November 2017 BOTM
                    1978 GS1000C - May 2021 BOTM
                    1982 GS1100E - April 2024 BOTM
                    1999 Honda GL1500SE

                    Comment


                      #25
                      That tray area is in the last photo is where I found all my starter clutch screws. I had that same broken area tig welded.

                      My guess is when the starter clutch bolt was longer the counter weight on the crank flung the bolt into the case.
                      GS\'s since 1982: 55OMZ, 550ES, 750ET, (2) 1100ET\'s, 1100S, 1150ES. Current ride is an 83 Katana. Wifes bike is an 84 GS 1150ES

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                        #26
                        Yeah, I'm trying to find someone to weld it, but as soon as I mention "motorcycle crankcase" they say they can't do it! WTF?
                        Ron
                        When I die, just cremate me and put me in my GS tank. That way I can go through these carbs, one more time!https://www.thegsresources.com/_forum/core/images/smilies/cool.png
                        1978 GS750E - November 2017 BOTM
                        1978 GS1000C - May 2021 BOTM
                        1982 GS1100E - April 2024 BOTM
                        1999 Honda GL1500SE

                        Comment


                          #27
                          Originally posted by 1978GS750E View Post
                          Yeah, I'm trying to find someone to weld it, but as soon as I mention "motorcycle crankcase" they say they can't do it! WTF?
                          It's because of the oil. It's gonna splatter because oil gets into the pores of the metal. Best soak the entire area in MEK or similar to degrease.
                          Ed

                          To measure is to know.

                          Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                          Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                          Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                          KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                          Comment


                            #28
                            They are scared of all the oil & the fact that it has to be oil tight... I bet a lot of welders have been burned welding something & then having it leak later. Any hot rod shops around you? Maybe they'd be more inclined to take a look at it...
                            1980 GS1000G - Sold
                            1978 GS1000E - Finished!
                            1980 GS550E - Fixed & given to a friend
                            1983 GS750ES Special - Sold
                            2009 KLR 650 - Sold - gone to TX!
                            1982 GS1100G - Rebuilt and finished. - Sold
                            2009 TE610 - Dual Sporting around dreaming of Dakar..... - FOR SALE!

                            www.parasiticsanalytics.com

                            TWINPOT BRAKE UPGRADE LINKY: http://www.thegsresources.com/_forum...e-on-78-Skunk/

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                              #29
                              Belzona or Devcon would be the answer over here. You will have similar there.

                              To be cured at room temperature and used as a steel filler, this grey plastic steel putty allows you to efficiently plug cracks or breakages where you would not be able to repair t | Cromwell Tools


                              ---- Dave

                              Only a dog knows why a motorcyclist sticks his head out of a car window

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                                #30
                                Thanks Grimley, I have a bunch of Devcon metal filled epoxies, since I used to sell them! I'm hopeful that I can find a welder that will tackle this, as I am concerned about the epoxy bonding to the oil-soaked aluminum. I feel a weld is the way to go if I can get it done. We shall see! I don't want a piece of epoxy coming loose and rattling around in there, doing more damage!
                                Ron
                                When I die, just cremate me and put me in my GS tank. That way I can go through these carbs, one more time!https://www.thegsresources.com/_forum/core/images/smilies/cool.png
                                1978 GS750E - November 2017 BOTM
                                1978 GS1000C - May 2021 BOTM
                                1982 GS1100E - April 2024 BOTM
                                1999 Honda GL1500SE

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