-
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.
Looky what folowed me home.
- Thread starter JTGS850GL
- Start date
Actually I've already adjusted the valves and then did the compression test afterwards. On top of that I've drained the oil and replaced the oil filter. There was a distinct smell of gas in the original oil so I filled and drained it again after I did the compression test. As reported above, the compression test yielded a 142-148 range between the cylinders.
The main reason I was asking about testing the motor before hand was to minimize my down time of the GS1000. I'm going to have to do the replacement by myself, unassisted, so I'm thinking it will take a little while to pull the original motor and put this one in. That's assuming that there's no one local that would be willing to give me a hand.
Just didn't want to run into problems afterwards. So I guess it's bite the bullet and begin the removal of the current engine.
Last edited:
Doing some preparation in advance to the engine transplant. Decided to pickup a tool that should come in handy:
Harbor Freight was running a sale and I had an old gift card laying around so with the sale price of $79 minus the $20 gift card it came in at under $65 with tax. Figure I can use it to remove and reinstall the generator in my motor home and probably will come in handy for several other tasks. It can lift up to 1500 lbs so should work out pretty well.
Harbor Freight was running a sale and I had an old gift card laying around so with the sale price of $79 minus the $20 gift card it came in at under $65 with tax. Figure I can use it to remove and reinstall the generator in my motor home and probably will come in handy for several other tasks. It can lift up to 1500 lbs so should work out pretty well.
I planned to use a piece of plywood to bridge the lift with the frame and simply slide the old engine out and the new engine in while the bike sits on it's center stand.
Just to make sure that everything is in good working order, I tested the gear position sensor and found it to be rather high in resistance. The resistance seemed to vary from 12 ohms to 300+ ohms so it pulled the sensor and sanded it down to clean the contacts. After that it measured no more then 6 ohms in any gear and neutral.
Next thing I want to do is verify that the ignition pickup I transferred from my 1980 GS1000GL Frankenstein engine is in good working order.
Just to make sure that everything is in good working order, I tested the gear position sensor and found it to be rather high in resistance. The resistance seemed to vary from 12 ohms to 300+ ohms so it pulled the sensor and sanded it down to clean the contacts. After that it measured no more then 6 ohms in any gear and neutral.
Next thing I want to do is verify that the ignition pickup I transferred from my 1980 GS1000GL Frankenstein engine is in good working order.
A little progress today on the 1100G transplant. Here's where it sits today:
1000G engine out and 1100G engine ready for install. Total time from start to now was right at 2 hours.
That included test fitting the new V&H 1100E exhaust to the 1000G engine:
This is what I'm most concerned about on the reinstall.
Any suggestions on the best way to get that darn driveshaft and boot connected without tearing the boot up?
Planning on buying a new boot before the engine install. The old one is a little hard and I can see some cracking.
It does give me an opportunity to get things cleaned up on the frame before the install. Lots of dirt and silver overspray:
Planning replacing the following while I'm at this stage:
Driveshaft boot
Drive shaft clamp
Drive shaft boot spring
Clutch cable
Any other suggestions on what should be replaced?
1000G engine out and 1100G engine ready for install. Total time from start to now was right at 2 hours.
That included test fitting the new V&H 1100E exhaust to the 1000G engine:
This is what I'm most concerned about on the reinstall.
Any suggestions on the best way to get that darn driveshaft and boot connected without tearing the boot up?
Planning on buying a new boot before the engine install. The old one is a little hard and I can see some cracking.
It does give me an opportunity to get things cleaned up on the frame before the install. Lots of dirt and silver overspray:
Planning replacing the following while I'm at this stage:
Driveshaft boot
Drive shaft clamp
Drive shaft boot spring
Clutch cable
Any other suggestions on what should be replaced?
Last edited:
H
Higgibaby
Guest
When I removed and reinstalled my motor I was down to the frame, I just laid the motor on its side (with no fluids in mind you) laid the frame over it and attached the engine mounts and propped it up. Took about 10 mins in all
Frame now repainted and ready to accept the motor.
I'm going to attempt to slide the motor in with the rear swing arm still attached. If it proves to be too much of a PITA I can always pull it then. Here's how she looks now.
G&S Suzuki told me that they shipped my parts today so I should be able to get the engine in within the next week or so.
I'm converting the choke to the newer 82+ style lever choke.
Now need to figure how I'm going to plug up the hole where the old pull choke was. Any Suggestions?
In the process I found that the 9 wire connector that went to the left hand controls was melted together.
The Frankenstein bike made another donation today and now everything is in good working order. Changed out the handlebars to a chrome set that Chef contributed. A little better sitting position. The old set had me laying too far forward for my liking.
I'm going to attempt to slide the motor in with the rear swing arm still attached. If it proves to be too much of a PITA I can always pull it then. Here's how she looks now.
G&S Suzuki told me that they shipped my parts today so I should be able to get the engine in within the next week or so.
I'm converting the choke to the newer 82+ style lever choke.
Now need to figure how I'm going to plug up the hole where the old pull choke was. Any Suggestions?
In the process I found that the 9 wire connector that went to the left hand controls was melted together.
The Frankenstein bike made another donation today and now everything is in good working order. Changed out the handlebars to a chrome set that Chef contributed. A little better sitting position. The old set had me laying too far forward for my liking.
Couldn't help myself and purchased a set of these to go with the V&H exhaust:
I offered him $4 each and he took it so total cost will be $32 shipped. I know, I know it's expensive, but I love stainless steel studs and I love even more the broached Hex socket head. The nuts are also serrated so no need for lock washers.
I offered him $4 each and he took it so total cost will be $32 shipped. I know, I know it's expensive, but I love stainless steel studs and I love even more the broached Hex socket head. The nuts are also serrated so no need for lock washers.
UGHHH!!! Still waiting on parts from G&S. I'm thinking of dropping the engine into the frame just to feel like I'm getting somewhere.
In advance of install day I did some little things. Bench synced the carbs, Shortened they intake clamps by trilling a new hole and cutting the end off. The original clamps were too stretched and didn't want to wait for an online Suzuki dealer to send the parts. Worked for my 850 just fine.
In advance of install day I did some little things. Bench synced the carbs, Shortened they intake clamps by trilling a new hole and cutting the end off. The original clamps were too stretched and didn't want to wait for an online Suzuki dealer to send the parts. Worked for my 850 just fine.
Edit: Woo Hooo, just received a UPS update and the parts from G&S have been picked up and are on the way. Parts should arrive on Friday! Lets see now. I ordered the parts on Jan. 29th and they finally left G&S on Feb. 10th even though they gave me a tracking number on the 6th. Sure feels like a LOOONG time. I guess I'll be ready for the engine transplant by this weekend. Just in time for a cold spell to come rolling in. I hate working in the cold. Need to get the garage cleaned up and heated.
OK, we have progress today. Engine mounted and most bolts installed loosely. The only bolts to still put in are the drive shaft bolts. I didn't have any loctite on hand so I'll save that for the next day. I was able to line the bolt holes up and easily thread one bolt in loosely so I see no issue there. I folded the driveshaft boot back and everything lined up without damaging the boot on install. Don't think it would be so easy with an old hard boot though:
Engine electricals connected up and engine now cranks. Never had to remove drive shaft or rear swing arm. Did take an hour or so and two jacks to get the engine to be maneuvered into place but once I got the rear through bolt in everything else fell into place. One person job as long as you have patience:
Decided to go with chrome case guards instead of the black painted ones that were on there before. Contrary to what I've read it looks like the 1000GL case guards will fit the 1000G frame with no issues:
Engine electricals connected up and engine now cranks. Never had to remove drive shaft or rear swing arm. Did take an hour or so and two jacks to get the engine to be maneuvered into place but once I got the rear through bolt in everything else fell into place. One person job as long as you have patience:
Decided to go with chrome case guards instead of the black painted ones that were on there before. Contrary to what I've read it looks like the 1000GL case guards will fit the 1000G frame with no issues:
Last edited:
bigboresuzuki
Forum Newbie
Have you plugged the choke cable hole yet? Got to be a Suzuki badge I reckon.
Getting a little closer to complete. Fired the engine today and it sounds good. No strange sounds or vibrations coming from the engine and the exhaust note sounds sweet. Absolutely no oil leaks. Got to love the OEM gasket sets.:clap:
Lots of smoke on initial fire but stopped after a few minutes. I think they fogged the cylinders for storage since the plugs were coated with an oil film that wasn't dirty at all. After several restarts there is no smoke warm or cold. Compression on all cylinders was right at 160 to 165 across the board warm. Nothing lower then 160 and nothing higher then 165.
Synced the carbs. Only problem so far is a slight hanging idle at around 2K RPMs. If I push down lightly on the throttle linkage it returns to normal @1100 and stays there when I remove my finger. Does it even when the throttle and choke linkage are disconnected so I'm thinking something on the throttle shaft is binding or the return springs are weak.
Looks like I'm going to have to change my sig soon:biggrin::
Temporary fuel tank for syncing carbs:
Still waiting on new pad but this worked temporarily to plug the choke cable hole:
Lots of smoke on initial fire but stopped after a few minutes. I think they fogged the cylinders for storage since the plugs were coated with an oil film that wasn't dirty at all. After several restarts there is no smoke warm or cold. Compression on all cylinders was right at 160 to 165 across the board warm. Nothing lower then 160 and nothing higher then 165.
Synced the carbs. Only problem so far is a slight hanging idle at around 2K RPMs. If I push down lightly on the throttle linkage it returns to normal @1100 and stays there when I remove my finger. Does it even when the throttle and choke linkage are disconnected so I'm thinking something on the throttle shaft is binding or the return springs are weak.
Looks like I'm going to have to change my sig soon:biggrin::
Temporary fuel tank for syncing carbs:
Still waiting on new pad but this worked temporarily to plug the choke cable hole:
Last edited:
Finally!!! Got her all put back together and everything bolted up. Took her for her first voyage today. No hiccups, shifts very smoothly, great torque, no oil leaks and no hesitation all the way up to redline! Best of all... No vibration!!!
Now I just need to get her to a suitable location so I can take some pics for my sig. Rain coming now and then cold weather there after. Still waiting on some cosmetic goodies as well but here is the way she looks today:
Now I just need to get her to a suitable location so I can take some pics for my sig. Rain coming now and then cold weather there after. Still waiting on some cosmetic goodies as well but here is the way she looks today:
NICE! Looking forward to seeing it daylight.
H
Higgibaby
Guest
Wow, looks amazing! Congrats
