The 81 GS1000 Cylinder Mystery

[Call Me Ahab]

Greetings guys!

I've been working on my gs1000, currently combing the engine - and when I took calipers to my engine's cylinders, I discovered something has me veerrryyy puzzled.

My readings say these cylinders are 2.754, 2.749, 274 etcetc. If this is accurate, which I have all reason to believe it is, my engine was bored out to 1100 cc... If this is indeed the case, how do I replace these bloody rings??

Can I buy a set from an 1100 standard? I just don't know what to do now - tomorrow I'll take it in to a mechanic and have him double check my findings, but for now I am quite certain that it is overbored.

Any ideas on how to replace those rings, and what with? Where will I find the right set? I see some on eBay, are they reliable?

[rustybronco]

You really should be using the proper equipment to measure the cylinders. With that said are you measuring the bottom of the cylinders and do you know if the calipers are indeed accurate?

[rustybronco]

I just checked my GS1000 shop manual and it said the stock bore is 2.755 to 2.756 inches. (70.000 to 70.015mm)

[Big T]

Greetings guys!

I've been working on my gs1000, currently combing the engine - and when I took calipers to my engine's cylinders, I discovered something has me veerrryyy puzzled.

My readings say these cylinders are 2.754, 2.749, 274 etcetc. If this is accurate, which I have all reason to believe it is, my engine was bored out to 1100 cc... If this is indeed the case, how do I replace these bloody rings??

Can I buy a set from an 1100 standard? I just don't know what to do now - tomorrow I'll take it in to a mechanic and have him double check my findings, but for now I am quite certain that it is overbored.

Any ideas on how to replace those rings, and what with? Where will I find the right set? I see some on eBay, are they reliable?

You do have a shop manual, right?

[Steve]

I agree with the above, wrong tool and wrong information.

The 1000 has a bore size of 70.0mm, which is 2.755".

The 1100 has a bore size of 72.0mm, which is 2.835".

You can download a factory manual from BassCliff's site, click HERE.

.

[Call Me Ahab]

Alas, I am a fool.

You really should be using the proper equipment to measure the cylinders. With that said are you measuring the bottom of the cylinders and do you know if the calipers are indeed accurate?

No, I am measuring from the top - is that wrong? Yes, the calipers are completely accurate - I remeasured with metric though and after talking to Steve, I see that my panic was premature.

I just checked my GS1000 shop manual and it said the stock bore is 2.755 to 2.756 inches. (70.000 to 70.015mm)

Indeed, my new measurements read within 69.99-70.01

You do have a shop manual, right?

Yes, it is a 2nd edition Haynes Manual, but I'm starting to get nervous about using it.

I agree with the above, wrong tool and wrong information.

The 1000 has a bore size of 70.0mm, which is 2.755".

The 1100 has a bore size of 72.0mm, which is 2.835".

You can download a factory manual from BassCliff's site, click HERE.

.

Will be downloading tonight. I guess my math is just wrong on how engine displacement is calculated - I figured I was using 2.75 x 4 = overall displacement...

Of all the searching I;ve done tonight I did not bother to double check the ORIGINAL dimensions! That would have saved me some grief.

I'm currently consulting (pestering, the poor soul) a member of the forum who is advising me on how to not ruin the engine. He has already stopped me from causing significant damage to my #3 cylinder. Which, granted, looks damaged already.

Thank you, everyone, I appreciate your knowledge and time!
Now I'm off to lap my valves, chip off what paint remains, and powder coat my jugs / cyl top and cyl cover =]



************
This is a photo of the carbon buildup on my cylinder that has me wondering what to do...
http://s1355.beta.photobucket.com/us...9c7f8.jpg.html

[Steve]

I guess my math is just wrong on how engine displacement is calculated - I figured I was using 2.75 x 4 = overall displacement...

No, sorry, displacement is calculated by calculating the displacement of each cylinder, then multiplying by the number of cylinders.

In your case, the bore and stroke for the GS1000 are 70.0mm and 64.8mm. The displacement (volume) of a cylinder is pi (3.14159) times the radius squared times the height, so 3.14159 * 35 * 35 * 64.8 = 249.38cc. Multiply that by the four cylinders and you have 997.5cc, or a nominal 1000cc.

.

[Call Me Ahab]

No, sorry, displacement is calculated by calculating the displacement of each cylinder, then multiplying by the number of cylinders.

In your case, the bore and stroke for the GS1000 are 70.0mm and 64.8mm. The displacement (volume) of a cylinder is pi (3.14159) times the radius squared times the height, so 3.14159 * 35 * 35 * 64.8 = 249.38cc. Multiply that by the four cylinders and you have 997.5cc, or a nominal 1000cc.

.

Ahhh... my bad =] thank you. Currently reviewing the info you sent over... Trying to figure out where to get the rings from. eBay or vendor =X

[chuck hahn]

Get stock OEM Suzuki rings. Thats my opinion.

[Call Me Ahab]

Get stock OEM Suzuki rings. Thats my opinion.

Recently lost the job that provided most of my income, at the moment I'm left with a weekends only retail job... Money is a critical deciding factor, I found some "HY" brand rings on eBay that I plan to use... If I could afford $30 a piece for sets, I'd do it - I know that they're higher quality. In this case, I just cannot afford it =[

[koolaid_kid]

Be sure and gap the rings before you install them.

[Call Me Ahab]

Be sure and gap the rings before you install them.

Yessir, Steve sent me detailed instructions on how to handle that - I just need to get some files for when I'm ready to reassemble. Would a dremel and a grinding wheel work for this?

[Big T]

powder coat my jugs / cyl top and cyl cover

Powder coating can't take that much heat

[Steve]

I just need to get some files for when I'm ready to reassemble. Would a dremel and a grinding wheel work for this?

If you use a fine wheel and make sure the ring is well-supported (they are surprisingly brittle), then be sure to remove any burrs, that should do fine.

.

[MK3Brent]

Powder coating can't take that much heat

How hot do the valve covers get?

300-400?F would probably be your operating limit.

My source:

http://www2.dupont.com/Powder/en_US/assets/downloads/technical_info/Alesta_Technical_Guide.pdf