GS-Dunx Posted January 11, 2020 Share Posted January 11, 2020 Dear forum, For some time I have been working on rebuild of an 81 Suzuki GS1000ET. I'm now at the stage of commissioning the engine. The engine itself has been checked for compression, had internal inspection with a bore scope and I have spun the engine without plugs and confirmed oil pressure. I have given the outside a good clean and tidy and I have taken both side covers off to take a good look. No issues found - It certainly looks like I've got a good engine so I did not embark on a full rebuild. I thought it may be a good idea to drop the sump and just check for any 'nasties'. To my surprise I found a washer and a screw and I am now onto a game of 'hide and seek' to find where these have come from. The good news is the sump is clean, there are no metallic particles and the screw and washer are complete and undamaged, so wherever the came from they have not done any damage to the engine and I would guess have been resident in the sump for some time with its last owner. I have already identified the washer as the inboard thrust washer from the starter intermediate gear and verified its absence by removing the cover again to take a look. It seems that this must have fallen out when someone last took the alternator cover off. Needless to say I'm happy I understand where it came from and it is now back in its correct place. The real mystery is where the screw has come form - The screw is an M6 x 25 set screw with a JIS cross head. Myself and one of my colleagues at work (who is also a GS fan) have been trawling parts guides and manuals to see where these are used inside a GS1000 engine and the only use we could find were the three oil pump retaining screws (I think these are Suzuki part 0211206257). I removed the clutch assembly today to check expecting one to be missing but all are present and correctly torqued so the mystery deepens! I don't suppose there are any GS1000 engine experts out there who may know where screws of this size (or Suzuki part number) are used in a GS1000 engine - this may help me target my hide and seek for the missing screw. Any helps and assistance anyone can give would be greatly appreciated :-) Best regards, Duncan. Quote Link to comment
Reinhoud Posted January 11, 2020 Share Posted January 11, 2020 (edited) Picture? Cam chain guide holder, in the center of the crankshaft has 2 of those screws... Oilpump might have those screws too, that means, take the clutchbasket off to inspect, Oh I just see that you checked that already.. The alternator is also held in place with screws if I remember correctly, but the screws might be longer than 25mm, but coming loose and end up in the sump might be a bit far fetched. Edited January 11, 2020 by Reinhoud Quote Link to comment
Askamaskinservice Posted January 11, 2020 Share Posted January 11, 2020 Welcome to OSS. Quote Link to comment
dago Posted January 12, 2020 Share Posted January 12, 2020 Check the screws that hold the clips for the wires inside the generator cover Quote Link to comment
Gixer1460 Posted January 12, 2020 Share Posted January 12, 2020 You may not find any screws missing - its easier to replace one than go opening up an oil tight engine to retrieve a dropped one! 2 Quote Link to comment
GS-Dunx Posted January 12, 2020 Author Share Posted January 12, 2020 Many thanks to those who have responded,. please forgive me, I'm new to the forum so not sure how to respond directly to individual posts... Dago, I did check the alternator wire clip screws, the threads in the casings all seem too short. There are three screws holding the stator in place, however it is unlikely that these could 'escape' without causing damage to the inside of the alternator 'drum' on the end of the crank and mine is spotless. Interestingly all of the 'screws' on the alternator stator and cable guides are fitted with hex head bolts so not original cross head screws. Reinhoud, this is sounding a bit like a complete engine strip if it is the case.... I did see some similar screws in the guides but they seem shorter in length. Do you have a diagram you could point me to online. If I can see the part I can check if the part number is the same. If it is I may be able to see it by removing the cam cover and using the bore scope down the chain casing to look for the missing screw. I have a photo but cant attach it (can only attach a web address). Will attach a pic when I work out how.. Gixer1460, I definitely think this may be the case. The thrust washer behind the intermediate starter gear took a few attempts to locate, and when it did drop out during assembly it ended up on top of the casing rib - I think that this is what must have happened some time ago - the hex head bolts on the laternator may be evidence of previous 'lost bolts' Any askamaskinservice, many thanks for the welcome. My GS thou is an 'ongoing' project that was started before, house wife and kids - needless to say its taken some time but it is nearing completion. Always good to know there are forums like this where you can seek good advice and helpful tips :-) 1 Quote Link to comment
gs7_11 Posted January 13, 2020 Share Posted January 13, 2020 (edited) Welcome Dunx. Just to be pedantic, and you might find it less confusing when searching for and ordering parts, there's no such thing as a 1981 GS1000ET. The bike might have been registered in 81, but it is a 1980 model. The 1981 model suffix was X, but the GS1000 was deleted for 81, although they were still around in dealers. As were 79 N model bikes in 1980. Edited January 14, 2020 by gs7_11 Quote Link to comment
Reinhoud Posted January 15, 2020 Share Posted January 15, 2020 https://www.cmsnl.com/suzuki-gs1000-1979-n-general-export-e01_model13512/partslist/FIG-11.html#.Xh5kbsgzaM8 Quote Link to comment
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