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Re-Instatement of 83 GSX750 EZ from a 7/11 to a 750 & creating a new 1100

Good to see the 1100E's but sorry to hear about your accident.
I hope you get fully mended and strong again soon. Nice Jobs.
 
So i installed the valves back in the head and mounted the head back on the cylinder block.Cam shafts went in and as i was about to start installing the cam shaft clamps i realised i had 1 broken bolt in the head. It was on outer edge so i covered the internals and drilled it out. The easyout went straight in and i pulled the broken bolt out. I couldnt believe it had gone so smothly.
the Camshafts went back in and i installed all the cam shaft clamps and tightened the bolts. Torquing up the 2nd to last one on inner 4 bolt clamp and snap. Another broken bolt. I tried drilling a hole in this bolt but couldnt quite get my drill vertical to access it.
option 1 - Pull everything apart, take the head off and drill it out on the bench
option 2 - just leave 3 bolts on that clamp
I went for option 2 as i dont even know if the engine will fire up yet with enough compression.
I should get exhaust on this weekend so i can crank it over and see if i have enough compression.
i really should have tapped all the threads while i had head on the bench as exhaust bolt holes are not good and i will probably have issues there as well.
I will take head back off after compression test and Tap all bolt threads.
 
So i finally got around to doing compresion test. 70 -75 all round so thats not good. I have pulled the head and block off and will do some measuring to see which direction i head. There is nothing obvious like broken rings to explain the lack of compression.
Any suggestions on likely issues?
 
ensure said:
So i finally got around to doing compresion test. 70 -75 all round so thats not good. I have pulled the head and block off and will do some measuring to see which direction i head. There is nothing obvious like broken rings to explain the lack of compression.
Any suggestions on likely issues?
Click to expand...

If the ring packs are not stuck and the bores look ok (measured up ok?), then it may be overheated rings at some time in its history. Happened to me once, spent the hottest day of the year in London traffic all day long and next morning the bloody thing wouldn't start. Compressions were almost zero. Taking it apart revealed nothing visibly wrong, but my major suspicion was on the rings given the immediately prior running condition.
 
So it has been a while that this project has been on hold and i am just about there but i have 1 issue. When i start the engine there is a loud noise (sounds like metal scraping) coming from lhs of engine. As soon as the engine starts the noise stops completely so i have to assume starter clutch. / motor. I have just replaced both but it is still happening. The cog on back of rotor can be wiggled a small amount. Is this normal? I had to replace starter motor as the teeth on the shaft had been ground down and 2 teeth on the starter gear had been broken off so eventually notthing happened. The loud noise did stop . Once i replaced starter motor it whirs around very happily. I have just installed replacement gear and the horrible noise has returned.
Any thoughts on what i should look at next?
 
What David said. Worth a look. Someone else recently had the same issue on here. There was a piece of one of the rotor magnets slapping around in there till I imagine centrifugal force stuck it in place, then it quiets down.
 
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