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Thread: 1983 GS1100E project

  1. #11
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    Welcome back to the site.
    Love the RD.
    2@ \'78 GS1000

  2. #12
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    https://imgur.com/8vLnl2t

    Going to see if this works

  3. #13
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    Quote Originally Posted by rphillips View Post
    What kind of disturbing clunk, the GS1100E shouldn't do that.
    I have enough of the motor apart that I think I know where the clunk was coming from (if not the why) and plan to make a post or series of posts if my dumb-a%^ can figure out how to do pictures (other than thumbnails). Was just trying to use imgur, and i can get a link, but not anything that looks like what I saw in "how to" post. I'll ask for you to bear with me as I figure this out.

  4. #14
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    Hey, I'm getting smarter! or at least i figured one thing out. This is "volito" in her glory days

  5. #15
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    salty_monk is offline Forum LongTimer GSResource Superstar
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    Welcome back

    1980 GS1000G - Sold
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    1980 GS550E - Fixed & given to a friend
    1983 GS750ES Special - Sold
    2009 KLR 650 - Sold - gone to TX!
    1982 GS1100G - Rebuilt and finished. - Sold

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  6. #16
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    So, as mentioned, I put it up on the work bench a few weeks ago. In the time since, I have been removing as many of the motor parts as I can to make it lighter and facilitate removing it from the frame. There have been a few complications so far. One of the cam cap bolts broke off below the surface of the head. I think it must have been broken before I started working as I just unscrewed the bolt. Didn't realize it was broken until I noticed that it was shorter than the others. It was in the locator tube in the lower right of the pic below (correction - this isn't the right pic - should have been from other side, but you get the idea).



    I used a spring loaded punch tool to divot the top. Then I used an extra drill bit to increase the divot and give myself matching faces and used JB weld to bond the bit to the bolt. It was just strong enough.



    The next problem was the head bolt on the exhaust side between the NO 1 and 2 cylinders. It was completely locked and rounded off when I tried to loosen. (center left in pic below)



    After failing to find a nut extractor that would fit, I had to resort to a painstaking process of using a flex shaft extension on a dremel and alternate between a ball and side cutter bit to machine enough of the bolt away to get it off.



    successfully removed head.



    Have to go work for a bit, but will try to post again a bit later with next problem and suspected source of the "clunk".
    Last edited by racerxnico; 10-14-2021 at 11:16 AM.

  7. #17
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    Baatfam is online now Forum LongTimer Past Site Supporter
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    Progress!

    (And photos!)
    Bob T.

    "That which you manifest is before you." -- Enzo
    "I always prefer to believe the best of everybody, it saves so much trouble." -- Rudyard Kipling
    "...for our existence to hold any value, it must end. To live meaningful lives, we must die and not return." -- Number Six

    '83 GS1100E ~ '01 TRIUMPH TT600 ~ '99 TRIUMPH TROPHY 900 ~ '67 HONDA CUB



  8. #18
    rphillips is offline Forum Sage Past Site Supporter
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    Awaiting the "clunk", looks like we should be getting nearer.
    1983 GS1100E, 1983 CB1100F, 1991 GSX1100G, 1996 Kaw. ZL600 Eliminator, 1999 Bandit 1200S, 2005 Bandit 1200S, 2000 Kaw. ZRX 1100

  9. #19
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    the clunk?

    When inspecting my starter clutch I was surprised to find that two out of the three spring loaded pistons wouldn't come out of their respective recesses (bores) and the third wasn't doing its job (the spring had collapsed enough that it wouldn't actually push against the metal cylinder (roller).



    It appears that the rollers had hammered into the metal around the recess enough times with enough force to deform it a bit and even crack it creating small edges that the shoulder on the pistons couldn't get by. I had to use the trusty dremel with flex shaft and ball cutter, while holding the piston down, to machine back the edge to get the pistons out.



    eventually I was able to free them (you can see one out here and one still stuck in its bore).



    While studying the part, I also noticed, aligned with the bottom of the bore, some deformations on the piece of metal that wraps the solid part. It looks like the pistons slapped back hard enough to dent the case (similar deformation aligned with all three bores).



    The first thing I want to do is confirm that this should be a smooth round part with no "bump out" aligned with the bores. Does anyone have one they can look at? I was surprised (lucky?) the bike never gave me any starting issues. So this evidence looks like it aligns with the sound I was hearing (I hope I don't find other evidence of hammering further in, but who knows). My best guess at this point is that it was maybe a carburation issue that was causing it to maybe want to back fire or miss (shrug, not really sure if that makes sense) or possibly cam chain issue? Something that was making the crank want to rotate the wrong way for a millisecond, grab the starter clutch rollers and throw them back. Again, shrug. I would love to hear any theories, because what I've found certainly looks more like a symptom than a cause.

    Oh, also, I am a combination of poor and cheap and reluctant to spend $180 on a new starter clutch. I'm going to keep my eyes open for a cheaper replacement option while I rebuild. If none come along, I'm going to try and reuse this one (it was starting fine before parked) with some new pistons, springs and shim (rollers seem fine). If it does end up giving me grief down the road it isn't so difficult to get to and replace later.

  10. #20
    rphillips is offline Forum Sage Past Site Supporter
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    I'd not seen this on a Suzuki, nor heard the clunk. A buddy has a CB1100F Honda & several yrs. back it started giving trouble starting. Starter would spin but didn't want to engage the crankshaft. Hit the button several times & it would finally start but getting worse. The Honda was about the same as the Suzuki set up. We got it apart & all looked good except the springs were all distorted, looked like they had been binding in the little slots & also they were about to push thru the outside of the hub. Bad cracks & hump where they were almost pushed thru. His rollers & little pistons were fine, just the springs & hub. New springs & a good hub from ebay & all has been good since. His never clunked, just had trouble engaging the crank. Glad you found it.
    1983 GS1100E, 1983 CB1100F, 1991 GSX1100G, 1996 Kaw. ZL600 Eliminator, 1999 Bandit 1200S, 2005 Bandit 1200S, 2000 Kaw. ZRX 1100

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