• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

Bought another one! Let the work begin!

There are windows in the cases underneath the main bearing. That is a starter clutch bolt. It is short because it broke. It is beat to *@%^$*@%^$*@%^$*@%^$ because it bounced around under the number one piston and rod after it found its way through the window.
 
Since that's an internal web my guess is you will be okay with that piece broke out. Oil will sling and fill up that cavity though which may be a bigger problem. One other option is shape a replacement piece and have it TIG'ed in place, then file it flat. I'd be inclined to go that route but since the aluminum has been in oil for 30+ years the welder may experience a lot of splatter.
 
My apologies Norm and TeamDar! After removing the crank I can see where the bolt could have gone through one of the two passages. Weird thing is that there is no scaring in the stator area and no missing bolts!

I guess someone could have picked up an extra bolt while the stator was off and it got magnetically held while they put it back together??? Who the #$%%& knows?

Yeah Nessism, I was thinking the same thing about the TIG welding. I wonder if a high-grade metal-filled epoxy would work?
 
Got a set of stock pistons today for the pig! Cylinders should be here on Friday. Ordered new rings from Cruzinimage.net. Have a bunch of gaskets to order from Parts Outlaw. Still have to find someone to do the TIG welding.

I might have this thing together by Halloween, ..........or Thanksgiving, ........... or Christmas! Ah heck, lets shoot for Brown County next year!
 
That tray area is in the last photo is where I found all my starter clutch screws. I had that same broken area tig welded.

My guess is when the starter clutch bolt was longer the counter weight on the crank flung the bolt into the case.
 
Yeah, I'm trying to find someone to weld it, but as soon as I mention "motorcycle crankcase" they say they can't do it! WTF?
 
1978GS750E said:
Yeah, I'm trying to find someone to weld it, but as soon as I mention "motorcycle crankcase" they say they can't do it! WTF?
Click to expand...

It's because of the oil. It's gonna splatter because oil gets into the pores of the metal. Best soak the entire area in MEK or similar to degrease.
 
They are scared of all the oil & the fact that it has to be oil tight... I bet a lot of welders have been burned welding something & then having it leak later. Any hot rod shops around you? Maybe they'd be more inclined to take a look at it... :)
 
Thanks Grimley, I have a bunch of Devcon metal filled epoxies, since I used to sell them! I'm hopeful that I can find a welder that will tackle this, as I am concerned about the epoxy bonding to the oil-soaked aluminum. I feel a weld is the way to go if I can get it done. We shall see! I don't want a piece of epoxy coming loose and rattling around in there, doing more damage!
 
Might it be cheaper to go with a new block? As the owner of an '82 11E (painted to look like yours), I feel like a relative. :D
 
New block? These things are made of unobtainium!

At least with this one, I know what I've got!
 
1978GS750E said:
New block? These things are made of unobtainium!

At least with this one, I know what I've got!
Click to expand...

Well, Chef1366 and a few others tend to collect '82 and '83 11E parts. Chef was my go-to guy when my EZ bucked me off and continued without me.

And a really good welder? Also unobtainium. Worth his weight in gold.
 
More work on the PIG!

More work on the PIG!

Got the cylinders today for the pig! Bores measured out great with very little out-of-roundness and look like new. (Is that a word? roundness?) A very light hone should clean them up just fine.

Other than the outsides looking like it was never washed, and it suffered a leaking head gasket at some time, creating lots of baked on oil and grime, I think they will work!

Ordered OEM gaskets late last night, and I have a highly-recomended welder lined up for this weekend. Who knows, I just might have this thing ready for Brown County next year!:cool:
 
1978GS750E said:
I have a highly-recomended welder lined up for this weekend. Who knows...
Click to expand...

If he wears a 1930's style leather aviator's helmet, you know he's the real deal. ;)

Of course, I'm not the one who shelled out the greenbacks, but I'm hoping things go so well that you'll stop using the P word! :p
 
The "P" word is a term of endearment! But compared to my 1978 GS1000, it "is" a big ole' pig! Straightaway speed is great, but the GS1000 handles twisties sooooooo much better! IMO
 
New cylinders for the pig!

New cylinders for the pig!

Got the cylinders cleaned, old gaskets removed, honed and painted today.:cool:
WLpNhyt.jpg

Dropped off the crankcase at the welders this morning. Hope to have the crankcase back by Thursday.
 
Not much done today on the pig! I did get the fuel gauge sending unit de-rusted and the float back on the stem! Checked it and it works! Ordered new clutch discs and started another list of small parts that will be needed!
 
Last edited:
Rob S. said:
If he wears a 1930's style leather aviator's helmet, you know he's the real deal. ;)

Of course, I'm not the one who shelled out the greenbacks, but I'm hoping things go so well that you'll stop using the P word!
Click to expand...

You have to consider Ron is the guy that "once owned a Harley".​
 
You must log in or register to reply here.

Similar threads

S
The Great & Terrible Ask "which exhaust headers not made for the 650G fit the 650G"
Replies
1
Views
71
jdub6092
jdub6092
G
1982 GS1000 Z US Version
Replies
10
Views
190
slayer61
slayer61
miked
He's back, and with another 1100G
Replies
2
Views
90
miked
miked
DR Payne
1983 GS550E: The Scenic Route
2
Replies
22
Views
390
DR Payne
DR Payne
Chuck78
GS500 electronic ignition into GS400/425?
Replies
9
Views
187
kochic
kochic
Back
Top