Bought another one! Let the work begin!

[1978GS750E]

Found this pig and decided that I needed a winter project? It is a 1983 GS1100E that needs a LOT of things done before it is roadworthy. Most urgent is a leaking head gasket and replacing the Vance & Hines that does not have a baffle!

Well....... since I am off work today............might have to do a few small things.

 

[1978GS750E]

After about 4 hours I was ready to see what was really going on with the oil leak.

 

[1978GS750E]

Got the head off and all looked OK. Cams and all surfaces looked good. Then I got the cylinders off and found this!

And this:

 

[Nessism]

Wow! Hopefully the crank can cases are okay!

 

[1978GS750E]

Pulled the sump cover and the bottom was filled with about 1/16" of real fine metal grit and these larger pieces:

Oil filter was suprisingly clean without any noticeable grit or metal pieces.

Now the question is, do I pull the engine and split the cases to wash it out, or put it back together without splitting the cases and hope for the best? Either way, looks like I'll be in the market for a new set of pistons and jugs or a complete engine.

The PO said it had a 1134 kit in it? I haven't measured the bore yet to verify.

 

[1978GS750E]

Just measured, and it does have (or actually, it did have) a 1134 kit in it! Bores measures aprox. 74.70mm with my cheap dial calipers. I believe stock bore is 72mm.

Looks like new cylinders and pistons are in order for this one!

 

[Nessism]

It might be possible to install a sleeve to fix the cylinder. Chef1366 Bill might have some parts laying around...

 

[1978GS750E]

Found some more metal in the sump filter:

So I had to get the screen off to see what was inside!

Looks like the engine cases are coming apart! Gotta see whats in there!

 

[Redman]

. . . . . .. . . . . . . . . . I believe stock bore is 72mm.

. . . .!

Yes. (same as 1100G)

 

[Redman]

Man !
All the sudden the head gasket leak isnt that much of a concern.

 

[Guest]

Got the head off and all looked OK. Cams and all surfaces looked good. Then I got the cylinders off and found this!

And this:

Yikes.

 

[Carter Turk]

I have cylinder just like that too...looks like a starter clutch grenade on cylinder # 1.

When I split the cases I found all the rounded off starter clutch screws resting in a tray like area in front of the starter motor.

 

[1978GS750E]

The really wierd thing is that when I test rode it, it ran fine! Of course with the un-baffled header I couldn't hear much of the engine noise. I just hope the crankcase internals are OK!

 

[dorkburger]

Ashame about the engine damage, but it looks like a nice bike overall, that minor detail aside.

 

[1978GS750E]

Might have found the cause of all this mess! Split the cases today and found this:

Found the broken case pieces along with a knurled head bolt???

My guess is that someone dropped a bolt and it bounced around causing all this damage. Cannot see one missing anywhere inside the cases?????

Gotta do more searching.

 

[storm 64]

Looks like maybe it's a stater clutch bolt. Maybe the starter clutch let go and caused all the damage...

 

[Nessism]

More bad luck. Sorry for all the hassle.

 

[Buffalo Bill]

Ok, situation like that can happen. New engine? New block? Keep the pistons?
Bonne chance

 

[Rob S.]

Just realize the 1100ED is arguably the pinicle of air cooled Superbikes. And exhaust baffles? We don't need no baffles!

 

[1978GS750E]

Yeah Norm, a starter clutch bolt was my first guess too. But there is no way that a starter clutch bolt can get into the #1 piston/crank cavity???? The odd thing is that this is the only part of the case broken. The top half looks like new on the inside. Here is a picture showing a wider view of the broken area:

Now my question is......can I repair the broken area since it looks to not have any real pressure on it?

All the rods (except #1 has a few nicks) and bearings look and feel great. No other damage anywhere in the crankcase that I can see.

I am guessing that someone dropped a bolt into that #1 piston/crank cavity, ran it and the bolt bouncing around broke the cylinder sleeve and chewed up the piston skirt before breaking this area of the crankcase. Now since these crankcases are made of unobtainium, I guess a repair is in order, if possible.

I have a stock set of pistons and cylinders headed to me now. My thinking is that the 1134 kit has such thin sleeve walls that it caused the sleeve to break easier than normal. (of course, the bolt is going to break something!)

Sound plausible? Can it be repaired?

Thanks!