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1983 GS1100ES Engine Rebuild.

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    1983 GS1100ES Engine Rebuild.

    Well, my winter project is well underway and progressing fairly well, taking into consideration work, kids, and all the other joys of life that keep us out of the garage...

    I'm the proud owner of two 83 GS1100s.

    My first is a 1100E with a little over 32k on the clock. It's stock with the exception of a sprocket conversion and a 4-1 kerker.



    My Second is the 1100ES blue/white paint scheme with a little over 19k on the clock. Upgrades included, a 4-1 exhaust, stainless break lines, sprocket conversion, and jet kit with pod filters.

    It's standing bare at the moment in my single car garage.




    Initially, I was not planning on doing a total rebuild on the engine, however, I soon realized that i had a significant issue that needed to be addressed. I was originally planning on only removing the head and cylinder jugs to repair a nasty base gasket leak on the back side of the engine around cylinder 3/4. It did run great, with compression over all was good with cylinder 4 being slightly lower.

    After removing the cylinders and cleaning up around the leak area i noticed some fine cracks along the webbing between cylinders 3 and 4.



    The cracks spiderwebbed all the way down and there was noticeable movement. Additionally, when i was removing the sump and the strainer I found some fine metal shavings. The source of which was from a bolt of the incorrect length in the clutch cover that was rubbing and shearing on the clutch hub. (PO had the basket welded and I'm assuming that reassembly didn't go quit right.)

    After consulting with a few friends and a great shop out my way, I determined that the only thing to do was to get new cases.

    Many people would probably scrapped the project at this point and ebay'd/listed a part out, but I was always a bit more heard headed than most...not to mention I LOVE to see these gorgeous bikes out on the road.

    Anywho, thanks to Fred over at Sky Cycles I was able to acquire a solid and clean set of cases which i further power washed/ brushed/ sanded as I am planning to bring the engine back to its OEM black glory upon reassembly.



    I really enjoy doing these things by hand however sometimes i wish i had some better tools/equipment to really take the job to the next level. However, I'm happy with the outcome so far.

    Currently, I'm awaiting some miscellaneous parts to continue on.

    Things I've finished are:

    1. Honed cylinders. Cleaned up nicely with good 45 degree crosshatching.

    2. Pistons: Good shape, and cleaned up nicely, with new rings installed.



    3. Lower and Upper Crankcase components installed including new cam chain:



    Just waiting on new crank shaft oil seal, OEM O-rings, and gearbox plugs, then I should be ready to seal it up.

    Things still on the list:

    1. Going to be tackling the head next couple of days. Supposedly it had a valve adjustment done shortly before purchase, however i want to check guides, change seals, check retainers/springs/lap valves/etc... while I'm in there.
    2. Rebuild clutch. The springs on the old hub were shimmed to prevent clutch rattle, then welded for strength. However, couple shims have some play and I've got a HD APE clutch kit so I think I'll be purchasing a new (used) hub to rebuild to go with the kit.


    3. Reassembly and Paint.

    WISH LIST:

    1.GSXR suspension conversion.



    I really envy some of you guys...A quick pick of my cluttered "work station," in my single car (or as the case may be duo bike) garage, located on the top of my portable table saw. And you might even be able to spot the every reliable and handy milk crates which are great stands and parts catches .



    I'll fill ya'll in on the rest of the project as it continues.

    Just wanted to give a quick thanks to all of you on the site. I don't ever really post and only recently joined as a member on GSR, however I've been reading as an anonymous guest for quite some time and am thankful for all the knowledgeable and helpful people here on the forums!

    Cheers and wish me luck.

    Nic
    83 GS1100ES rebuild:

    http://www.thegsresources.com/_forum...d.php?t=170032

    Budget GSXR Conversion:

    http://www.thegsresources.com/_forum...d.php?t=200563

    New to me bike: 2008 B-KING

    #2
    Keep up the good work.
    Feel The Pulse!

    1982 GS1100E with Tracy one piece body
    2007 Roadstar Midnight Warrior

    ebay cntgeek

    Comment


      #3
      Looks great Nic.

      Thanks for taking the time and posting all the photos!
      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


        #4
        "the grass is always greener" I'd kill for a single car garage sir


        My little shed is driving me nuts......

        Comment


          #5
          Great work so far, I will be following your thread. When you have more room in a garage, you find more things to put in there!

          Comment


            #6
            Still trying to track down 750 drive/driven gears. Think I might have found some on the Bay.

            OEM suzuki gaskets are begining to arive. They can get expensive, but I've been getting lucky finding them here and there for significantly less than simply ordering from bikebandit. I am using a Cometic base gasket set, as I've had good results with them in the past. But, everything above the cases (and internal plastics/rubbers) are all OEM.

            I even purchased a top end kit from Athena Gaskets to make a comparison on the quality between OEM. Needless to say the OEM gaskets do look to be more soundly made with better material, and while they may be more expensive, I highly recomend that they be used over any of the Kits out there.

            Also, having a Suzuki manual is invaluable for the detailed information it provides. I also have a Haynes but it is mysteriously oblique in certain areas, and at times ommiting important installation information. Thanks to Basscliff for having those manuals readlily available on his homepage. http://members.dslextreme.com/users/bikecliff/

            More to come!


            Nic
            83 GS1100ES rebuild:

            http://www.thegsresources.com/_forum...d.php?t=170032

            Budget GSXR Conversion:

            http://www.thegsresources.com/_forum...d.php?t=200563

            New to me bike: 2008 B-KING

            Comment


              #7
              Finishing up the clean up on the cylinders.

              Base Gasket was a pain. Will clean/prep for paint/lube tomorrow.

              Still gotta get the darn cylinder ring gaskets out some how. Fused into the gap.



              Sprayed down the cylinder walls with WD for now.
              83 GS1100ES rebuild:

              http://www.thegsresources.com/_forum...d.php?t=170032

              Budget GSXR Conversion:

              http://www.thegsresources.com/_forum...d.php?t=200563

              New to me bike: 2008 B-KING

              Comment


                #8
                Originally posted by niclpnut View Post
                Still trying to track down 750 drive/driven gears. Think I might have found some on the Bay.
                I've got a set already out.83 GS750

                You are talking oil pump gears right?

                Comment


                  #9
                  Originally posted by SVSooke View Post
                  I've got a set already out.83 GS750

                  You are talking oil pump gears right?

                  Correct.

                  However, I needed the gears from a 77-82. Tooth count: 38 drive, 29 driven for higher output.

                  Found them at a local salvage for $25.
                  83 GS1100ES rebuild:

                  http://www.thegsresources.com/_forum...d.php?t=170032

                  Budget GSXR Conversion:

                  http://www.thegsresources.com/_forum...d.php?t=200563

                  New to me bike: 2008 B-KING

                  Comment


                    #10
                    I use a green scotch-brite pad on the gasket residue. Mixed with a small amount of WD-40 it gets the job done.

                    Comment


                      #11
                      OK the guy I was going to sell them to is looking a the wrong parts to

                      Comment


                        #12
                        Originally posted by SVSooke View Post
                        OK the guy I was going to sell them to is looking a the wrong parts to
                        AFAIK those gears are unique to the 83-? 750, the 1150 uses 1100 or 77-82 750 gears

                        Comment


                          #13
                          Got the cylinders cleaned up and lubed.

                          Honed.



                          Gasket surfaces cleaned. Residue scoured off with 3m pad.



                          Base gasket was a pain. Slipped once and made a very shallow groove.





                          Head next...

                          Nic
                          83 GS1100ES rebuild:

                          http://www.thegsresources.com/_forum...d.php?t=170032

                          Budget GSXR Conversion:

                          http://www.thegsresources.com/_forum...d.php?t=200563

                          New to me bike: 2008 B-KING

                          Comment


                            #14
                            Getting ready to close the cases.

                            Using the old case to organize the bolts...




                            While I was picking up and reorganizing i took a closer look at my cams:

                            Exhaust:


                            Some grooving/wear on lobe:



                            Enough to warrant purchasing a new set or upgrade?



                            Nic
                            83 GS1100ES rebuild:

                            http://www.thegsresources.com/_forum...d.php?t=170032

                            Budget GSXR Conversion:

                            http://www.thegsresources.com/_forum...d.php?t=200563

                            New to me bike: 2008 B-KING

                            Comment


                              #15
                              I'd say that lobe looks pretty bad. It will run but at the same time it will eat rockers like no tomorrow if the valve clearance it too tight.

                              If it's a stock cam, I'd change it. They don't cost much second hand.

                              Comment

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