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New GS1100 G Restoration Project. Rebuilding my Dad's bike
- Thread starter londonboards
- Start date
Day 85 Disconnecting the Shaft Drive
Day 85 Disconnecting the Shaft Drive
So thanks everyone. I got lots of advice and help that gave me ideas. Unfortunately for me I still had some learning to do. Let me see if I can run you through it:
I didn't know about the splined shaft at the wheel end. I imagined it to be another screw type affair (thanks bwringer). What I was trying to do (in my mind and in reality) was to break the link between the engine and the shaft drive at the universal joint near the engine end of the shaft by undoing the gold bolts (or at least darker bots) that join the shaft to the universal joint. The bolts point (by this I mean the head faces the engine and the threaded end points to the rear wheel) to the back of the bike and can be seen here (the one that the screwdriver head is touching):
My idea was to remove these bolts and then the shaft would be disconected and the engine could be removed. The problem is that without removing the rear swing arm (I didn't want to remove it as I wanted to wheel the bike to the garden to do the engine removal on it side "trick") it is very difficult to get to these bolts and remove them. Well I found it impossible.
See my blog here: My GS1100 Blog
There were problems so I removed the swing arm to get better access:
Now to get the shaft off. I started on the bolts that go into the engine casing:
This would allow me to get the shaft off surely (and quit calling me Shirley) but I didn't know it was the helical gear housing and not the shaft connector.
And that it would not come out completely as it hits the frame here:
So it was back to the idea of trying to get the shaft disconnected. But the shaft kept turning when you applied any pressure on the spanner. I had to use another spanner and lay it against the tops of 2 of the bolts and jam it against the frame in order to get any leverage. I did it in the end.
You can see the other spanner at the bottom of the picture. I didn't actually work like this but I did not get a photo of the actual arrangement I used.
That's how I got the shaft off. Now to get the engine out.
Day 85 Disconnecting the Shaft Drive
So thanks everyone. I got lots of advice and help that gave me ideas. Unfortunately for me I still had some learning to do. Let me see if I can run you through it:
I didn't know about the splined shaft at the wheel end. I imagined it to be another screw type affair (thanks bwringer). What I was trying to do (in my mind and in reality) was to break the link between the engine and the shaft drive at the universal joint near the engine end of the shaft by undoing the gold bolts (or at least darker bots) that join the shaft to the universal joint. The bolts point (by this I mean the head faces the engine and the threaded end points to the rear wheel) to the back of the bike and can be seen here (the one that the screwdriver head is touching):
My idea was to remove these bolts and then the shaft would be disconected and the engine could be removed. The problem is that without removing the rear swing arm (I didn't want to remove it as I wanted to wheel the bike to the garden to do the engine removal on it side "trick") it is very difficult to get to these bolts and remove them. Well I found it impossible.
See my blog here: My GS1100 Blog
There were problems so I removed the swing arm to get better access:
Now to get the shaft off. I started on the bolts that go into the engine casing:
This would allow me to get the shaft off surely (and quit calling me Shirley) but I didn't know it was the helical gear housing and not the shaft connector.
And that it would not come out completely as it hits the frame here:
So it was back to the idea of trying to get the shaft disconnected. But the shaft kept turning when you applied any pressure on the spanner. I had to use another spanner and lay it against the tops of 2 of the bolts and jam it against the frame in order to get any leverage. I did it in the end.
You can see the other spanner at the bottom of the picture. I didn't actually work like this but I did not get a photo of the actual arrangement I used.
That's how I got the shaft off. Now to get the engine out.
Last edited:
Hhhmmmm. My flange/shaft hit the frame so would not come out. Maybe because it's a GS1100?
Greetings
Greetings
Thanks so much. Heart warming comment.
After 87 days on the project (not full time you understand!) it is really encouraging (and we need all the encouragement we can get) to know people can see the humanity and emotional side of these rebuilds.
So much fun.
Greetings
After 87 days on the project (not full time you understand!) it is really encouraging (and we need all the encouragement we can get) to know people can see the humanity and emotional side of these rebuilds.
So much fun.
Greetings
Looked like fun! That rolling chassis weighs a lot so the best way to do the 'frame off the engine trick' is to take everything off the frame first.
The trolley jack / block of wood works better in my experience and you can use that really nice and slowly and controlled. It's the only way to get the engine back in without scratching your paint, bar spending a year down the gym beforehand developing biceps the Hulk would be proud of.
The trolley jack / block of wood works better in my experience and you can use that really nice and slowly and controlled. It's the only way to get the engine back in without scratching your paint, bar spending a year down the gym beforehand developing biceps the Hulk would be proud of.
Hey thanks. It was fun (kinda) and I have a lot to learn before I get it back in. Maybe at least a year away. Some guy sent me photos of how he does it: huge engine hoist, scissor jack AND a car jack. I will have to find a way of doing it without bashing the (what will be) newly painted frame and engine.
Greetings
Greetings
S
SVSooke
Guest
OK what weighs more,the engine or the frame?.IMHO the easiest way to get the engine back in the frame is to lay the engine on it's side and slip the frame over it.Done it that way with the 750 and the 1000.
Day 85 Engine Removal part 2
Day 85 Engine Removal part 2
Here is some more technical (ha ha) information about the engine removal process.
See my blog here: GS1100 Blog.
First of all you follow the manual:
That should be easy enough. It was written by Suzuki so they must have tried it themselves? We laid ours down on the grass:
Then nearly 2 hours later if came out:
And that is about as technical as it gets. Now the fun really begins.
Here's the video again: How not to remove an engine.
(Added 17/12/2012) I have just found a video that shows how it should really be done: How to remove an engine properly.
Greetings
Day 85 Engine Removal part 2
Here is some more technical (ha ha) information about the engine removal process.
See my blog here: GS1100 Blog.
First of all you follow the manual:
That should be easy enough. It was written by Suzuki so they must have tried it themselves? We laid ours down on the grass:
Then nearly 2 hours later if came out:
And that is about as technical as it gets. Now the fun really begins.
Here's the video again: How not to remove an engine.
(Added 17/12/2012) I have just found a video that shows how it should really be done: How to remove an engine properly.
Greetings
Last edited:
A
althomas101
Guest
Sight glass
Sight glass
Looking at your blog you had a question about the sight glass. What I have done in the past is to replace it with a watch crystal. They come in any diameter and you don't have to worry about them deteriorating like that down the road. Use epoxy or silicon to glue it in place.
Sight glass
Looking at your blog you had a question about the sight glass. What I have done in the past is to replace it with a watch crystal. They come in any diameter and you don't have to worry about them deteriorating like that down the road. Use epoxy or silicon to glue it in place.
Thanks for that althomas101.
Does it come out from the inside or outside of the reservoir?
How do you get it out?
Greetings
__________________
G
Guest
Guest
Boy, I have to say your Blog is top notch. Wish I had the time to do all that with my restorations. And the links you have are great. Very nice project, especially with the history of the bike. Subscribed!
Thank you. You are very kind.
Looks like a brilliant way to do things. Thanks allojohn.
You're welcome, I'm following you with interest.
Day 91 Engine Photos
Day 91 Engine Photos
Just to show you how much work I have to do. Here are some engine photos:
See them all on the blog: My GS1100 Blog
Bad corrosion at the back.
And front!
I reckon the "before" and "after" shots are going to be sensational (if we ever get that far).
Greetings
Day 91 Engine Photos
Just to show you how much work I have to do. Here are some engine photos:
See them all on the blog: My GS1100 Blog
Bad corrosion at the back.
And front!
I reckon the "before" and "after" shots are going to be sensational (if we ever get that far).
Greetings
Day 91 Starter Gear Assembley
Day 91 Starter Gear Assembley
I needed to put the stator cover back on in order to seal the engine for washing. It was quite a bind getting all the wiring inside and it was catching on the starter gear assembley. So I decided to take it out for the time being.
Full story on my blog: My GS1100 Blog entry or Full Blog: Full Blog
I lost the thrust washer at first. I heard it falling but couldn't find it. Ended up behind the starter clutch flywheel cog (?).
Greetings
Day 91 Starter Gear Assembley
I needed to put the stator cover back on in order to seal the engine for washing. It was quite a bind getting all the wiring inside and it was catching on the starter gear assembley. So I decided to take it out for the time being.
Full story on my blog: My GS1100 Blog entry or Full Blog: Full Blog
I lost the thrust washer at first. I heard it falling but couldn't find it. Ended up behind the starter clutch flywheel cog (?).
Greetings
Day 91 Engine Clean Preparation
Day 91 Engine Clean Preparation
You've all read the threads that look like this:
"took the engine out, cleaned it up, painted it and put it back in".
Don't think my entries will ever be so simple. Well you can see I have the engine out. Now it needs cleaning up before we start work on it. Just this one task is a big job in itself. We don't want any water getting into the engine do we? There's nearly 2 hours work right here.
So I put all the engine covers back on and need to close up the intakes and exhausts.
See the full story here: My GS1100 Blog
She won't miss the rubber gloves.
Greetings
Day 91 Engine Clean Preparation
You've all read the threads that look like this:
"took the engine out, cleaned it up, painted it and put it back in".
Don't think my entries will ever be so simple. Well you can see I have the engine out. Now it needs cleaning up before we start work on it. Just this one task is a big job in itself. We don't want any water getting into the engine do we? There's nearly 2 hours work right here.
So I put all the engine covers back on and need to close up the intakes and exhausts.
See the full story here: My GS1100 Blog
She won't miss the rubber gloves.
Greetings
