1983 GSX1100E

[saffa]

I used GS1000 clocks on mine. plug and play with regards to speedo,tach and fuel gauge. Blends nicely with the round headlight

[Villeboi]

Does anyone  know if mk1 bandit carbs fit original gsx air filter box or is it possible to fit bandit air filter box in gsx frame? I have spare bandit carbs lying around and tought that I could use them in this bike as the gsx ones are bit sorry looking and had to drill one mixture screw out as they were all seised pretty well. Have read that it's difficult to get bandit carbs to work with pod/panel filters so using stock airbox should be better. 

Or maybe just buy brand new Mikuni RS carbs so wouldn't have todeal with old used carbs maybe. Bit pricey but what wouldn't be with these bikes.

[Villeboi]

Okay thanks, have to take a look on that route then. I have bandit airbox rubbers laying around so I'll try to modify the gsx airbox to take those maybe.

[Villeboi]

Todays job was to torque the cam shaft caps and as I was tightening one of them the bolt just snapped inside the head. The bolt wasn't even bottomed out when it snapped so maybe they were just old and tired who knows. 

So just decided to remove the head and I'll have to take it to a machine shop to ask them to take it out. Some of the cam shaft bearing caps threads already had helicoils in them so someone have had problems with them in the past also. Might be good time to replace valve stem seals also.

Cylinder bores looked okay, bit of carbon deposit on top of the bore. Been thinking about putting bigger pistons in but we'll see what happens and what is the condicion of rest of the engine.  

[Villeboi]

While struggling with the snapped bolt I also noticed my bandit carbs were leaking badly from the fuel hose t-piece that connects carb #2 and #3. Is there any aluminium/brass upgrades with o-rings available out there? I svear I have seen those somewhere but could only find ones for gsx1100 original carbs but I guess those are different size? Or should I just stay with new original plastic t-piece and original seals, those are bit expensive thou.

[Dezza]

Litetex supply these in their rebuild kits.

https://www.litetek.co/Carb_Kit_Suzuki_GSF1200_95-00.html

[Villeboi]

Got the engine disassembled today. Found couple of suspisios things inside. 

First thing is the missing washers from the starter idle gear. The gear has been grinding on the casing. Should there be one washer on each side?

#1 connecting rod has some weird marks on it and the piston pin is bit tight going through

Inner clutch basket has pretty deep marks on it. Outer basket has some minor wear too.

Transmission has pretty bad looking wear on some of the gears. Not sure if these are usable or would it be best to find better gearset. Gears went in good and there wasn't any weird noises coming from it.

[Villeboi]

I'm also not sure if this engine has too little head gasket as there seems to be marks on the gasket and pistons where the piston has been contacting the headgasket. Pistons have 0.5 markings on them so maybe overbore pistons? They are still Suzuki pistons tho.

Oil sump and oil pickup mesh were also quite dirty. Oilpan had lots of black sludge.

These small clutch spacers things had been worn down quite a bit.

Not sure what to do with this engine. There's quite a lot wrong with it but I wasn't expecting a brand new anyway. One thing I'm sure is that who ever worked with this engine previously shouldn't have touched it.

[Gixer1460]

Sort of typical for a high mileage engine IMO. Pan dirty but no big chunks or silicone. Clutch hub worn out, spring spacers always suffer but can be reused. Never understood 'square' gasket and piston looks like it's been touching! That touching has possibly caused the marks in the small end? from side loading. Gears will probably go for years in regular use, competition use - you roll the dice!

[Villeboi]

Yes the gearbox didn't whine or anything like that and gears went in good or as good as they go in these old engines. I quess they'll be fine in my use but I'll have my eyes open for better condition set.

I think I'll up the cc of the engine a bit so I need new pistons and head gasket anyways.

[TonyGee]

1 hour ago, Villeboi said:

Yes the gearbox didn't whine or anything like that and gears went in good or as good as they go in these old engines. I quess they'll be fine in my use but I'll have my eyes open for better condition set.

I think I'll up the cc of the engine a bit so I need new pistons and head gasket anyways.

the gears looked like that on a bandit engine i had, it was the noisiest box ive ever heard !!!!!  had to replace the rough gears, it was then quiet as a mouse.

plus the gearbox on my GSX1100 is smooth as silk. 

 

[Arttu]

12 hours ago, Villeboi said:

Not sure what to do with this engine. There's quite a lot wrong with it but I wasn't expecting a brand new anyway. One thing I'm sure is that who ever worked with this engine previously shouldn't have touched it.

I think it depends a lot on what you are expecting from the rebuild. If you want it to run trouble free for years and tens of thousand kilometers you need to be more strict. For quick and cheap "just get it back running" you can skip many things.

Transmission gears look pretty bad for me. I think they will wear quickly after reaching that point. Maybe they can still run for quite long with some growing whine but no any guarantee how long. On the other hand finding used gears in better shape can be difficult and new ones are expensive...

Con rod marks look more like some assembly fuck-up than wear, from what I can see. I would try to carefully blend them down with sand paper to see if the pin starts moving smoother. Replacing the con rod is pretty complicated and expensive.

Clutch and oil pan look normal for an used engine. Try to file down the notches on the hub. Check the springs on back of the outer basket. Usually they are worn and loose if they haven't been replaced already.

[Villeboi]

I was looking for used gearboxes but seems that all used ones have those same exact teeths in as bad condision as mine. And it looks that you can't get new gears for these early engines. You can get new ones for EF/EFE and I found an old thread here where someone put EF/EFE gears in older 1100 motor. Altho those new gears were nearly 700€ so not cheap. Does anybody have any experience about these gearboxes interchangebility?

[Russ750ET]

It looks like you can get new gears for your bike. They are showing as available on CMSNL.

I was going to suggest pinching the parts numbers and going over onto WeBike.com. But for the first time I've seen, CMSNL actually seems to be cheaper (but still really expensive).

[Villeboi]

This is only one that I found that they have in stock. All the others are not available. I need #5,7 and 35

[DaveV65]

have you tried these guys? Suzuki GS1000 Close Ratio Gearbox – Nova Racing Although looking at the price you may have to sell a kidney or a limb!

[Villeboi]

Or both, yeah bit pricey for my budget. 

[Villeboi]

Anybody knows what these type of connectors are called or where to get new ones? These are bit molested and brittle.

Also simplyfied the wiring harness by deleting some unnesessary wires and stuff.

And made some brake hose brackets

[Wee Man]

Try here for connectors 

https://kojaycat.co.uk/epages/950000457.mobile/en_GB/?ObjectPath=/Shops/950000457/Categories/Yamaha_Wiring_Loom_Connectors[1]

[Villeboi]

Thanks

[Villeboi]

Continued with the wiring. Removed the turn signal control unit and seems  that you can just remove it and turn signals still work normally. Unneeded wires pile is growing bigger.

Are these solder and tape jobs from factory? I guess they are, judging by the different colour tapes.

I still need to finish the wiring loom ( run out of crimp connectors) and make bandit right hand switch assembly work with gsx connector.

[Captain Chaos]

Suzuki don't solder wires.

[Guest]

They do actually. Or did ar least on all the GSs I've made looms for.

Joints inside the loom are soldered and taped. That's how you can have all the black/white earth wires commoned up, for instance. Just check the wiring diagram.

[Captain Chaos]

On the looms I have (EFE and later) the wires are crimped together, not soldered.

Happy to be proved wrong of course.

[Villeboi]

This had 1 joint that was crimped, all the others I've found have been soldered and taped. But not sure tho if some previous owner have been soldering these. I might check all the other joints and crimp them and put heat shrink over them, I think that'll be better than 40 years old tape anyways.