Major 1100 Kat rebuild...last post.

[solo suzuki]

For people running stock 16 inch wheels the 17" GSXR wheels will help you gain some of the clearance lost to a shorter fork.

because radials have a lower profile, the switch to a 17'' will most likely give you a wider patch and better grip but no significant gain in ground clearance.i've stuck one in what use to house a 16'' (GS1150EF), the air forks will give you some leverage but unless you want your bike to look like a moto X the solution / problem i think is the pipe.

katman's suggestion: 4-2-1 is the way to go, or build a sleeper with the stock exhaust!!!

ps: billy, where's your avatar???

 

[Anonymous]

I couldn't find a 4-2-1 for an 83 gs1100e. I didn't look for too long though. Vance and Hines had a clearance sale on 4-1 super sports.

 

[Guest]

I am sorry to say I have hit a real snag with my project. The motor has come back incomplete and many things either don't fit or are missing. It is going to be some time for me to sort it out.

When I do I will post again with motor and performance updates. Thanks for all the info and input.

It's been a gas.

Rob

 

[Hoomgar]

Sorry to hear that Rob
Was it negligence that the motor came back that way?
And if so, are they going to make it right?

My project seems to have come to a halt as well but due only to $$$
:-({|=

 

[solo suzuki]

It is going to be some time for me to sort it out.

what up! katman??? can't just stop the saga now!... 8O
details please! :?

 

[Guest]

It's all very sad.....

My motor is destroyed....head and cases.......un-usable, wrong crank, piston and barrel damage...What a mess.

I have to start all over with another motor

Fun Wow.

 

[Anonymous]

Katman - when you get a chance, please let us know what happened. Details would be appreciated. I'm building one and others are also. It would help us to know.

I am sorry to hear about the problems.

 

[Billy Ricks]

Kat,
Are you going to stick to the GS motor? If you're not stuck on GS you might consider a GSXR powerplant like the Bike of the Month.

 

[skip]

man am i sorry to hear that, I hope you didn't lose to much money in your mis-adventure. I once put my 1150 motor back together after a major rebuild only to drive it about three miles and have the head ruined. Turns out when i was mounting the coils I must have dropped a nut in the cam chain valley and it got caught on the crank sprocket and made the cam chain jump a couple of teeth. All of my exhaust valves and some of the intakes had damage and i was really bummed out. I bit the bullet and installed new valves and lived almost happily ever after.

 

[Guest]

Well.....

As you know the motor came back in pieces. The trans was together but no block or head or side covers.

something happened to the cases so the clutch cover won't line up right and can't be bolted on. An oil pump bolt was broken off in the case and the who ever tried to remove it blew a hole in the cases and tried to gum the hole up with gasket cement and the mounting hole is all ground off and useless.

the porting job on the head I am told has ruined flow as well as some grinding had been done to the combustion chambers that has left serious grooves and inconsistancies in them. Some of the valve seats have been ground down as well leaving me with no angles or sealing.[scrap one freshly powder coated head with 500.00 worth of work].

The gasket surface of the block has dings and grooves from who knows what creating a posible sealing problem.

Installation gouges in the pistons where the wrist pin clips are that will need cleaning up.

the motor was filled with sand blast material and metal filings as was the oil pickup screen. The oil pump itself wouldn't even turn a full turn.

A number of the case holes need heli-coils and it has the wrong crank in it. It is an 1100E crank with the large rotor.

There are lots of missing nuts and bolts and it is time to cut my losses.

All in all it is about a grand plus the cost of new cases head and block and maybe...I hope not new pistons @ 700.00.

OUCH...........

Anyone want to buy a set of smoothbores 33mm Mikuni's round slides?
345.00 USD. 450.00CANADIAN

 

[Anonymous]

Katman, were the cases ever split on this motor. If so, did you do the work or did someone else?

Wrong crank? Did you buy this motor? How did it get the wrong crank?

You say the block has major dings. It looked so good in the picture. Did you notice them then, or did it get damaged later?

I'm asking about the cases because if they were sandblasted and not taken apart to be cleaned - then sand will be inside - for sure. Sandblasting is very abrasive anyway for aluminum.

I wish I was a little closer, I give you a hand. Your bike looks so sweet. I'm really sorry to hear the news.

 

[Anonymous]

Was this done at a shop or by a "friend" doing work for you? If it was done by a shop I'd like you to post their name. I would look into filing civil charges against them too and possibly for theft if you go back and see parts of your motor around. That's not right at all. :?

Steve

 

[Hoomgar]

Yes something doesn't sound right at all. If you paid to have this done and it comes back looking like cave men worked on it i would consider your legal rights in the mater. You shouldn't have to foot the bill for that.
No way no how.

:x

 

[Guest]

all the work was done by someone else

they were fine before the work..the damage to the block isn't that bad the machanic said he can take off 10thou and that should do it. He said that without it he may have to use some gasket seal.

the crank was sent out for welding. I got the trany back together but with the wrong crank installed.

buddy told me he cleaned the cases three times...but ....literally full of filings..

 

[Anonymous]

all the work was done by someone else

they were fine before the work..the damage to the block isn't that bad the machanic said he can take off 10thou and that should do it. He said that without it he may have to use some gasket seal.

What about the oil pump screw hole?

the crank was sent out for welding. I got the trany back together but with the wrong crank installed.

Did they send you the wrong crank? Did the shop that did the work put in another crank?

buddy told me he cleaned the cases three times...but ....literally full of filings..

3 times is nothin. I cleaned my block more times than that and I didn't sandblast it. You have to be anal about cleaning parts - especially after introducing abrasives.

Did you ever get it fired up - or is all this damage evident putting it together?

The shop that did the work sounds incompetent.

 

[Guest]

I had a guy putting it togethe who is supose to be a drag racer..works out of his back yard shop.

took the unfinnished motor to a shop of wide reputation and discovered damage after taredown for inspection of assembly.

I don't see how all the fragments could be missed by the first mechanic. the second shop deals with blast and powder all the time and has no problems. They build super bike motors and have an excellent rep.

The motor looks sabotaged...Pieces of metal laying all over the inside and the alum cam chain guide that bolts to the lower case was in 5 pieces..big pieces in the bottom of the motor.

Oil pump screw hole @ about 2 o'clock is completely buggered. most of it is ground away only a few threads left and there is a broken bolt in there.

Was not in that condition when I dropped off motor.

No it was never assembled completely ot be fired. If it had it would not have run. Mechanic #1 thinks the second shop sabo'd it and claims it was perfect when I picked it up from him.

I can't prove anything so I move on. Mech#1 is contacting the shop who did the crank to see if they returned the wrong one to him. Unlikely since it was done by a guy under the table. Iwas told that it was going to be a shop known to me but it wasn't.

know anyone with a 1100 kat motor 1982-83

 

[Paul]

That is a shitter.
If he is a race engine builder he should know about cleaning engine internals. How a cam chain tensioner is in 3 pieces f***ing amazes me. I drag-raced these engines, abused them, and helped alot of other guys out rebuilding engines etc, & I've NEVER seen anything that bad. Beleive me there are some idiots on the strips who don't know how a spanner works, they have trouble with a pair of pliers!
Is there a dispute between the dragrace guy & the shop, and you've been caught in the crossfire?
I would want something back off the bastards, because that is all they are, trying to get cash off you and just making a mess, then saying it isn't there fault.
Why not publish their names to make sure no-one else goes there to get ripped off.

 

[Anonymous]

Katman, if it was never fired and the oil bolt hole is ground away - then moving parts didn't do it. It sounds like mechanic #1 took a grinder to it. How can the cam chain giude be broken if it was never run? (never mind how can it break while running) How can bits of metal be inside the cases if it wasn't started? He built it - he is responsible - at least until the moment you fire the bike.

I'd file a small claims court suit. You have the testimony of shop #2.

 

[Billy Ricks]

Does this guy that screwed up your motor have a website or email address? We could bombarde the guy with some nasty emails. You should also let people here know so nobody deals with the bastard. It won't do you any good but it might save someone else some grief.

Years ago one of my brothers bought an old Panhead. It needed rebuilding so he had an authorized dealer do a topend on it. They had the bike for months. He finally got it back and it didn't run any better than before he took it to them. A few weeks later they were out of business. We ended up tearing the entire engine down and rebuilding it ourselves. Once the heads were pulled you could see they never touched it.

 

[Anonymous]

Our local Suzuki shop (40 miles away) replaced the valve seals on my gs1000g, well there were marks on the valves that made it LOOK like they did something...
They said all the clearences and guides looked like new and they replaced the seals, $220 and they didnt even clean up the carbon on the combustion chambers......

Anyways, she smokes in the mornin like she always did so I guess they probably looked it over and decided to pull the old wool over me eyes. Theres some shoddy shops out there guys...

BTW this is from Bartlesville Cycle Sports in Bartlesville Oklahoma if you were wondering, or even if you weren't. Dont go there, trust me