GS1150 ES Makeover Project

This motor is junk!
Get another one or get your money back.

[londonboards]

Damaged Engine Components

When you have this much metal spinning around inside the motor there is bound to be some damage.



Here is some of it.

Overheated con rods with shot small ends:



Scored piston pins:



And signs of damage to the inside of the cases where the clutch exploded:



Even taking a lump out of it:



Not completely irretrievable. Perhaps.

[londonboards]

wymple - it looks that way. But I am quite enjoying the tear down and if I can salvage it I will. These motors are pretty rare around here. Mostly all have been used for drag racing and are completely stuffed.

Greetings

[wymple]

Wouldn't it be maybe less expensive and less trouble to just source another engine?

[londonboards]

Engine Strip - Preparation

I had a couple of problems with bolts on the cases. One got rounded off and the other snapped.

See My GS1150 Blog - Getting the Cases Apart

I rounded this bolt off completely:



I was using this socket and it was too wide and close to the casing to sit correctly on the bolt head:





And I snapped another one using my power impact driver:



Greetings

[londonboards]

Engine Strip - Preparation

So I have decided to strip the engine and find out how much damage there really is inside. In for a penny (cent) in for a pound (dollar).

See My Blog - Suzuki GS1150ES - Engine Strip Preparation lots more hi-res pics there.

So here we go. Don't forget this little nut under the sprocket:



Top bolts out first:



Pistons 1 and 4 need to come off to get the crank out:



Then get the clutch off:



Along with other parts in this motor, I have an APE clutch nut:







I got the rotor nut off with my new power impact driver



But even with the correct tool it wouldn't come off.





Greetings

[Charlie G]

And I was looking forward to another 2 hour video of the struggle of the engine removal Richard!

Two points - you need to get your daughter some safety boots for manhandling engines and get rid of that 'sold' sticker on the screen; you're in this far so looks like it's a keeper.

I wasn't going to mention the "Health and Safety " thing, but you are getting the hang of this engine removal.

cg

[hampshirehog]

And I was looking forward to another 2 hour video of the struggle of the engine removal Richard!

Two points - you need to get your daughter some safety boots for manhandling engines and get rid of that 'sold' sticker on the screen; you're in this far so looks like it's a keeper.

[londonboards]

So We Are Taking the Engine Out

We decided that this motor really needs to be stripped down to check that all the metal bits that have been left in there by the PO are now out and that there is no damage to other parts of the internals. So the motor needs to come out of the frame. A much easier job to do when the head and cylinders are off:















Done (with some help).

Greetings

[tatu]

That head is JUNK! When the cam journals are KILLED like that, unless you can line bore the cam journals in the head, it is a throw away. Same with the cams & rocker arms. Sorry to see the head like that.
Ray.

A theory we talked about is that the valve springs and retainers definitely don't look stock, in your opinion, do you think that if the springs are too strong that it would lead to the kind of damage that we see on the cam lobes?
Also it seemed odd that the first orifice from the oil feed were the journals that were damaged, the inner journals further away from the feed are fine. Any ideas of what might be happening?
All that shrapnel in the last pics was inside the oil pick up only stopped by the gauze, likely restricting oil demand, but doesn't explain why the outer journals are goosed and the inner ones fine though they are on the same line, and all four are the same. The head and cylinder block/pistons all look new to me.
For sure someone has spent a great deal of cash on this bike at some time.

[posplayr]

Know I understand why you Brits can it a lump

[londonboards]

More Metal from Sump Filter

Got the sump filter off and discovered this little lot:



Bit included are parts of the piano wire retaining clip:



And this spring which I cannot place. Anyone have any ideas?



The ally bits were well rounded off, proving that they have been rattling around in this motor for some time:





No question about it now - this motor needs stripping down.

[rapidray]

That head is JUNK! When the cam journals are KILLED like that, unless you can line bore the cam journals in the head, it is a throw away. Same with the cams & rocker arms. Sorry to see the head like that.
Ray.

[londonboards]

But I could end up with a fresh motor. I know it has fresh pistons, rings, liners and a new clutch. As long as there is no other major damage, I just need to clean up the head and cams and bobs your uncle.

Greetings

[Fjbj40]

Laziness, there are lots of people out there who will put the minimum into something to try and recoup their money. Then they just **** other people!