Case Splitting 1982 GS1100e

[andrew93]

Well im finally getting around to fixing my 5th gear problem. Can i split the cases without taking the rest of the engine apart?

[Nessism]

Yes you can.

[andrew93]

Awesome. Anyone have any tips or things to watch out for before i dive in?

[Guest]

Get an engine stand. Makes it so much easier.
When splitting have it upside down so the tranny doesn't fall out.

[sharpy]

Get a workshop manual that you can download, read it. then read it again.. No such thing as stupid questions, only stupid people.

[rapidray]

FIRST, get a SUZUKI manual, NOT a Clymer or Haynes!! You don't need an engine stand, just a sturdy table to support the weight of the engine. Drain the oil & take the motor out of the bike. Pull the starter & upper case half bolts (make SURE you get ALL of them!). Pull the clutch hub & the 2 plates behind it that hold the cases halves together. You will need an impact driver for the Phillips head screws on these 2 plates. Remove the small "Z" shape plate in the countershaft area that holds the case halves together. Remove the stator & ignition covers & the ignition plate. Turn the engine upside down & remove the oil pan. Remove ALL of the lower case half bolts & then the cases will be ready to split. Feel free to call me at 714--356-784 five if you need help. I have been building & racing the 1100s & 1150s since they came out. Easy job!
Ray.

[andrew93]

Found the output shaft fork to be very worn and showing signs of heat.

[andrew93]

3rd gear( I believe its 3rd) has a lot of damage to the teeth and dogs

[andrew93]

Was it caused by a bent shift fork?

[andrew93]

I cant figure out how to get all the pics in one post. Sorry

[andrew93]

Another of the fork

[Nessism]

http://members.dslextreme.com/users/bikecliff/images/how_to_post_pictures.pdf

[Guest]

Plugged oil port

[rapidray]

Plugged oil port

How do you figure? Where all the burn is in his pictures are all splash fed areas? I would replace all the shift forks, & shift fork shafts if they are bent, & the damaged gears.
Ray.

[Guest]

How do you figure? Where all the burn is in his pictures are all splash fed areas? I would replace all the shift forks, & shift fork shafts if they are bent, & the damaged gears.
Ray.

So that is from a bent fork? Looks like oil starvation.