1983 Suzuki GS1100ED --- "Big Boy"

[Flaming Chainsaws]

Is this a clutch rattle? It only rattles at low RPM's and it goes away when the bike is fully warmed up.
http://www.youtube.com/watch?v=B8LSwLVQSBI

Thanks to TeamDar, I now have the correct sprocket nut.

I tested my stock R/R and the volts went up to 16v and counting! Bad R/R.... Replaced with my duaneage R/R and all is good .

Now I have another problem. None of my lights work except for the hi-beam and headlight. Did some looking around....

This is the suspect! The check panel control module.

Why do I think that? None of these wires match up. According to my manual, EVERY SINGLE WIRE SHOULD MATCH COLORS!

I will try to get another one.

 

[niclpnut]

Clutch rattle.

Springs on the back prolly loose. When it gets lubed and warm, sound tends to go away.

Nic

 

[Flaming Chainsaws]

Clutch rattle.

Springs on the back prolly loose. When it gets lubed and warm, sound tends to go away.

Nic

Easy fix right? Drain the oil, pull the clutch cover off, then tighten it. Or is there more to it? Is the clutch rattle a bad thing?

 

[Guest]

There's more to it... you have to take the clutch basket out and replace springs (in the basket) or use shims to reduce play in the loose springs. Some folks also weld the rivets at the back. Other than the noise it makes a rattly clutch is not a problem (I think).

 

[Flaming Chainsaws]

So I have to replace the clutch springs? If so, then I'll do it. They're cheap too . Is EBC good?
http://cgi.ebay.com/ebaymotors/EBC-...8179443QQptZMotorcyclesQ5fPartsQ5fAccessories





I think I found out the problem to why none of my lights work except for the headlight and hi-beam.

This is pulled out straight from the Hayne's GSX/GS1000, 1100 & 1150 4-Valve Fours manual.

The below is on page 174, section 15, paragraph 2.

The check panel is dependant on its supply from the oil pressure switch. If this fails, the check panel will not operate normally.

Now refer to page 54 and look at the last picture, 4.7 c.

And now compare that same picture to my oil pressure/temp switch.

With the above oil pressure switch, I cannot plug any electrical wire into it. Same thing for my top end oiler. This must be my problem right?



Do you guys know if the oil switch is normally grounded or not when the bike is running? If it is grounded, then I should be able to just ground the wire that should go to the switch then all is good... Or am I way off?

 

[Flaming Chainsaws]

I found the green/yellow wire (oil pressure). I also found the pink wire (oil temp).

I plugged the gr/y to the negative and nothing happened. Then I plugged the gr/y into positive and the oil light lit up.

Tried the above with the pink wire. Negative did nothing but when I plugged it into positive, the oil temp gauge started twitching. The exact same thing happened with the fuel gauge when I tried it.



So it seems that my electrical problem is because I am missing the oil pressure switch. What do you have to say?

 

[Guest]

For the rattly clutch you need to fix the springs in the clutch basket back plate, not the clutch springs. Do a search on the forum, it should give results with pics

You do have the oil pressure switch (in the middle of the cover plate) but it is missing a connector, see pic from the manual, that's where the green yellow wire goes.
However, the cover plate that you have doesn't have the oil temp pickup sensor, that's the one at the back on that pic from the manual.

 

[Flaming Chainsaws]

For the rattly clutch you need to fix the springs in the clutch basket back plate, not the clutch springs. Do a search on the forum, it should give results with pics

You do have the oil pressure switch (in the middle of the cover plate) but it is missing a connector, see pic from the manual, that's where the green yellow wire goes.
However, the cover plate that you have doesn't have the oil temp pickup sensor, that's the one at the back on that pic from the manual.

OK. I will do a search for clutch rattle.

I do realize that I have the oil pressure switch. But I have no idea how a wire would connect to it. And yes, my oil switch is missing the hole for a oil temp.

This is the stock oil pressure switch that I pulled off from this engine. Why would it not have the oil temp switch built into it? An '82 GS1100EZ gauge cluster also has the oil temp gauge, right?

 

[Guest]

I do realize that I have the oil pressure switch. But I have no idea how a wire would connect to it.

Have a look at the pic from your manual. there is a simple slip-on connector.

 

[Flaming Chainsaws]

Have a look at the pic from your manual. there is a simple slip-on connector.

I kinda see it but I don't even have that wiring. I don't think it's something that I can make either. And it's no longer available at any parts house .

My best hope is from The GSR . Already posted a wanted thread.

 

[ptexotik]

I'm going to be honest. I will not be keeping this bike. It's simply too big for me and it's a wreck waiting to happen.

then like me, you're going to love the look of the Katana ... not necessarily the ride! If you think the E is a handful ... trust me ...

 

[Flaming Chainsaws]

then like me, you're going to love the look of the Katana ... not necessarily the ride! If you think the E is a handful ... trust me ...

Yes, I think you said the Katana was heavier or harder handling? Can't remember.... I really do love the look of the Katana but again, too big of a bike for me .

I used to push my GS450 everywhere. Farthest I pushed it was almost 2 miles. If the 1100E breaks down on the road, there is no way that I'll be able to push it more than 100 ft before I pass out LOL!

But yeah, I did a quick ride on the big 1100E. The power of it is addicting but scary. My speedometer doesn't work but I had up to third gear and 5,000 RPM and just WOW! I really think the big bike bug has gotten me .

So as for the ride, it went fairly well but was just around the neighborhood. Smooth acceleration, no backfiring, good handling despite it's weight. Oh! And there's some oil leaks haha!

It's a hard decision.

 

[Flaming Chainsaws]

Did another ride around the neighborhood. This clutch rattle is really getting to me. It only happens under 1,500 RPM which is anytime I'm at a stop. If I pull the clutch in, the noise goes away and so does the vibration.

To my understanding, it is not necessary to fix this clutch rattle. But I want to. I can see it already. I'm on the road at a stop light and the guy next to me is saying, "Dude, your engine is ****ed."

I'll do a search on it here but you can go ahead and give me a play by play on how to fix it .


Now back to the charging issue. According to my manual, it should be at 14.00v-15.5v at 5000 RPM. For my bike, it's at 13.5v at 5000 RPM. Obviously a little low. It has the stock stator from a 1981 GS1100E, duaneage Honda R/R and brand new electrical connectors on the stator and R/R. Stator sends out 80v like it should so it's working good.



And I have more proof for my electrical problem (no lights). Turn to page 21, section 39 on your Hayne's manual.

ELECTRICAL SYSTEM FAILURE

Oil pressure switch defective. Check switch according to the procedures in Chapter ??. Replace if defective.

Oil pressure indicator lamp wiring system defective. Check for pinched, shorted, disconnected, or damaged wiring.

I don't have any of the above so it makes a lot of sense on why I have no lights .

 

[landshark]

If you like Katanas but dont want a big bike you could look for an import 400cc from japan if you guys get them over there?

 

[Flaming Chainsaws]

If you like Katanas but dont want a big bike you could look for an import 400cc from japan if you guys get them over there?

The smallest Katana the US got was the GS550M. There is also a 650 shaft drive I think. And I'm positive we have the 750, 1000, and 1100 Katana's. But they are rare! I can never seem to find one... If it's in poor condition, I'll still take it!

Importing is sort of a pain. Know a guy that imported a Japanese sports car and he had to make it meet US standards and all that. Not sure what you do with bikes though.

 

[landshark]

I was thinking more along the lines of maybe someone had already imported one and was selling it?
If i ever move back to Japan, or have enough money to leave a bike there to use when we visit i would probably get one of these.
http://www.suzukicycles.org/GSX-series/GSX400S-Katana.shtml

 

[Flaming Chainsaws]

I was thinking more along the lines of maybe someone had already imported one and was selling it?
If i ever move back to Japan, or have enough money to leave a bike there to use when we visit i would probably get one of these.
http://www.suzukicycles.org/GSX-series/GSX400S-Katana.shtml

They look cool . But I hear that the 4-cylinder 400cc bikes had problems with their crank shafts or something like that. I read that somewhere on here...

 

[Flaming Chainsaws]

For my clutch rattle problem, I will try tightening the big nut. What size is that? And while I'm in there, I'll try this.
http://members.dslextreme.com/users/storagecliff/images/quick_clutch_rattle_repair_by_tkent02.pdf

Then we'll see if it rattles or not.

 

[Flaming Chainsaws]

......

Didn't like the blue paint job that I did before. You could see all of the imperfections! Besides, it should be red .

Wet sanded the front fender with 220 grit. Nicely feathered edges. Is this good enough? Or do I need to remove all of the paint?

I just need to apply some rubbing alcohol then it will be ready for primer. But I'll do that after I sand down the right side cover.

 

[cowboyup3371]

Personally I would remove all the old paint so you have an even finish but don't just take my word as my stuff still didn't turn out great.