1100G low compression, burns oil.

[Redman]

If you search for a ''new'' engine, only the GK is rubber mounted, all the other G model are solid mounted.The crankcase is not the same. A 1100G complete top end will fit a GK.
Marc

Did not know that, Marc,
FOr the secondary drive project (a couple years ago, you might recall), I had entire engine unmounted and moved up and over a bit. I dont recall any rubber mounting. Maybe those cylindrical things (back - top of xmission) had rubber in them but I didnt notice.
At the moment, swapping entire engine is not an option I am concidering, but I should look into that crankcase-mounting situation.

 

[Redman]

Leading option at present is a salvage engine (from a fine GSR member) and me swapping the head and cylinder block (and? pistons), with rebuilding the head with new seals and probably new rings for pistons.

 

[kochic]

If you take you time its easy to do.Be careful with the pistons, all are NLA from suzuki and rings only std and .50 OZ. are available.I have 3 set of used gs1100gk pistons, let me know if you need something.GK engine are almost growing anywhere over here.
Marc

 

[Baatfam]

Any updates, Dave?

 

[Redman]

Any updates, Dave?

Thanks for asking.
Basically "No". Mostly stalled out, not determining how to proceed.
but might have some determination/progress tommorow.


I have been trying to measure the bore and pistons myself with expanding t guage thing and dial indicator (both cheap) and not getting reliable results that I can make any decision on. FOr one thing, the reading are like 71.95mm, when the spec is 72.00 (service limit 72.08) and some of my reading of pistons are larger than bore readings.
I ordered a more expensive (ahem, $40 not $18) dial indicator, but I suspect my problem is related to the expanding t thing and my procedure in general. (as others have told me, really need inside micrometer).

Just yesterday, I Found a one-guy-independent "motor sport" machine shop, mostly outboard motors and snowmobies but also motorcycles. Big thing he displays is "cylinder boring". I have something of an appointment with him in the morning, I asked if he could do the bore & piston measuring for me and give me a report. He asked again what engine and what year and how many miles (84k). He said, "yah, I can measure for you if you want (maybe he said "mic it for you") while you wait, but I can probably tell just by looking and feeling and tell you if it needs to be bored, or if pistons worn.

What I dont know is if overbored could be just enough to then use oversized rings, ..... . .. or if boring means need oversize pistons (which is not reasonable option).

Hopefully how it proceeds is I pay him maybe half hour labor to measure, and then I can decide how to proceed.

So maybe I am gonna find out pretty much what have already been told here : at 84K, dont bother measuring, just get lower mileage cylinder and pistons. I pretty much suspect that is what it is gonna be.

 

[Buffalo Bill]

Well Dave, if you really like the GK, you're gonna love it again after the work, Ah GARRONE TEE.
My G has regained it's youthful power after the valve job I did this winter. Whole lotta fun to ride again

 

[Nessism]

Boring means over sized pistons and rings. You can not use oversized rings in a standard bore, regardless whether or not it's worn or not.

 

[Redman]

Well Dave, if you really like the GK, . . . .

Yes, I do. I envision me having that for most remaining years of my riding carrier.
I am really comfortable on it, and I just like that it is such good cosmetic condition. And I like that I am so familiar with it.
(It is the RT that could go away, after GK back.)

My GK has never seemed like an 1100 to me (I have rode other 1100 that about rolled me off the back end).
Never seemed to even be up to the acceleration of the 850.
Was using oil when I first got it (2005 @29k miles). I had head rebuilt with new seals in 2007, and oil consumption was better for a few years.
Now at 84K, is burning much more.

Boring means over sized pistons and rings. You can not use oversized rings in a standard bore, regardless whether or not it's worn or not.

Thanks for explaining that.

 

[salty_monk]

Dave my 1100G definitely has a lot more oomph than an 850.... at 84k though I would guess you're losing it! I would hunt either a whole replacement unit or jug & pistons as you said.

 

[Redman]

WHat I didnt say is that about mid May 2020 I had a health problem. Pain for a few days, then uncomfortable and inactive for a couple weeks. ANd slow for a couple more weeks. And during this time THE elderly faterinlaw sick and in hospital and nursing home and hospital and then died, and we were statying with motherinlaw 2 - 3 days a week, 150 miles away, for months, and had another family tragidity during then. ANd then motherinlaw in hospital and nursing home and died. So that was all summer and most of the fall. And then was cold in the garage.

Had gotten a replacement head. But didnt get it taken care of till early this summer. And then was too hot in garage, at leeast was too hot for the level of enthusiasm I had for work on it.



NOTE: Now September 2021

Yep, Mr Dave ddanails, GK has been In my garage shop, since May 2020, sitting like this :

Your inquiry has prompted me to up my resolution to get at this project.

And now that not hot-humid in garage, I make more resolution to work on it most every day that am home (not with grandkids) at least a little, and one day a week for at least a couple hours. Hey, that might cut into my coffee shop visits. Hey, might cut into my disc golfing. Hey, might cut into morning photo walks on the pier.

Need to make significant progress before get into leaf raking season, cuz after that will be cold.

And now that I have told all you, I had better keep at it.

TO review:

Got cylinders measured at a motorsport machinist shop, deemed to be in spec.
Had them lightly hone the cylinders.

I have a complete gasket set (OEM).

Got a set of replacement pistons (Thanks again Mr Kochic.)

Got new piston rings (CruisinImage as recommend here).

Got a replacement head. ANd then had valves lapped in, and rebuilt with new seals (Thanks Mr Steve).

.

 

[Redman]

First work effort was to clean up around the bike. THen decide where to start.

Started with this:

To get at least some start on restarting the GK engine rebuild project ......

Started looking at getting some familiarity with piston rings. (taint never seen any of my piston rings before this project, and dont want to see any again afterwards).
Reading the factory manaul and practicing with the rings that came with the replacement/salvage pistons.

Was having trouble getting the two in the lower oil ring. Found that soup cans are about the right diameter, and cut them up with tin snips to make something of a ring compressor. That really helped. And managed to avoid slicing myself.... only a small nick.

Hose clamp around it might work for getting into cyclinder (why I made two).

 

[Redman]

Had some time yesterday and today.
Made some progress.

Cleaned up work bench some (probably still subject to comment from Trevor).

Took shop rags off engine cases.
Spent lot of time starring at it, thinking of where to start.

Stuffed shop rags back into opening, and scrapped remnants of base gasket.

Cleaned up the tops of replacement pistons, enough anyway so can better see the forward arrow.
Took off rings from replacement pistons, and installed the new rings.

Other progress (har har) was that after getting poked and sliced a couple more times, I found the sharp snag edge on my handmade-soupcan-ring-compressor. And got that removed. So Now maybe I will not be bleeding on stuff as much.

Got other stuff going on next few days. May be able get back to this project a little bit Friday and then more on Monday-Tuesday.

Progress is gonna be slow.
But have resolved to work on it at least some each day I am available. (And report here, so am accountable to you guys.)

Next. . . . ?
Pistons on con rods.

.

 

[Baatfam]

Good for you, Dave...

 

[Buffalo Bill]

Write a self published book: The Joy of Sitting on Concrete (The smell of Oil in the Morning).

 

[dorkburger]

Dave, I'm glad to see some progress. I think I've read here of people using plastic peanut butter jars as homegrown ring compressors. I'd image that its less sharp and has less friction vs metal.

 

[Rich82GS750TZ]

I tried coming up with something using thin plastic sheet and zip ties. It got very frustrating. I ended up just using my fingers. Start with the 2 & 3 up, get those in the jugs. Then rotate the crank to get 1 & 4 up just below 2 & 3, and work those in. I imagine another pair of hands would help, but I was able to manage. Take your time. I know Steve and others support the fingers-only method. It was Steve that got me to give up on the ring compressor idea.

 

[storm 64]

I use the finger method too. Also it helps a lot to have someone helping you. They can hold the cylinders while you're goofing with the piston and rings. One more tip. Be sure you don't overlap the oil ring holder (the wavy ring thing) its easy to do! Be sure you don't over lap the oil ring holder (the wavy ring thing) it's easy to do. Good luck and take it easy

 

[alke46]

Large hose clamps worked for me. I remember using 2 x 2 pieces of wood to hold the pistons just above the cylinder while easing everything down together.

 

[Redman]

Good for you, Dave...

Thanks. I post such minor updates, mostly to show am keeping my resolve.

Write a self published book: The Joy of Sitting on Concrete (The smell of Oil in the Morning).

hee hee or something that mentions 5 gallon buckets, engine degreaser, and a bandaid a day.

Dave, I'm glad to see some progress. I think I've read here of people using plastic peanut butter jars as homegrown ring compressors. I'd image that its less sharp and has less friction vs metal.

Ewww, good idea, and it doesnt have the ridges.

I tried coming up with something using thin plastic sheet and zip ties. It got very frustrating. I ended up just using my fingers. Start with the 2 & 3 up, get those in the jugs. Then rotate the crank to get 1 & 4 up just below 2 & 3, and work those in. I imagine another pair of hands would help, but I was able to manage. Take your time. I know Steve and others support the fingers-only method. It was Steve that got me to give up on the ring compressor idea.

okay, thanks, may abondon the make-shift-ring-compressor idea. (and I do know about the tapered area on bottom of cylinders). Have seen suggestion of suspending cylinders with something.

 

[Redman]

I use the finger method too. Also it helps a lot to have someone helping you. They can hold the cylinders while you're goofing with the piston and rings. One more tip. Be sure you don't overlap the oil ring holder (the wavy ring thing) its easy to do! Be sure you don't over lap the oil ring holder (the wavy ring thing) it's easy to do. Good luck and take it easy 

Only other time I ever did anything with piston rings was 1972, Sunbeam Imp. I dont recall too much, but do remember getting a lot of my fingernails trapped and sheared off by the rings. I intend to do better this time.
Have two 3 - 4 inch hose clamps to use with whatever make shift thing I use, or use the clamps only, or what ever improvise at the time.

Large hose clamps worked for me. I remember using 2 x 2 pieces of wood to hold the pistons just above the cylinder while easing everything down together.

Ah, the 2x2 to hold piston not only up but hold it level.


Lets see.... need base gasket and that tear drop oring in place......