1983 GSX1100E

[Russ750ET]

Tesa tape is great for finishing the looms. Not sticky and gooey like standard electrical tape. But it sticks to itself really well. If you overlap it a bit it gives the loom a lot of support, which is handy in the more venerable areas.

[Villeboi]

Got my cluch springs done by @Blower1 Old springs were bit loose, didn't rattle yet but I guess they would have soon. No heavy duty clutch backing plate needed with these power goals.

Also got myself cylinder block from @Blower1with EFE liners so it can be bored to 77mm. Top engine case is still to be machined to fit bigger liners. Need to get proper pistons for these at some point. Also got all new cylinder block studs.

And lastly I've been tinckering with the gearbox. 4th and 5th gears were cnackered quite badly. I now have 2 used gearset and 1 brand new input gearset/shaft And 1 used set is still on it's way, so I should be able to get working gearbox with these parts. It seems that 4th and 5th gears are quite common fault in these gearboxes.

[krazy kat]

EFE cylinders should fit 83 engine case without any machining 

[Villeboi]

I think this bike has not it's original engine as this has silver/non painted engine cases and unwelded small taper crankshaft with the small oil hole in the taper end of it. So early style engine I think, and the top case half is being bored to accept even bigger liner if I get power hungry later.

[Villeboi]

Any suggestions for 77mm piston kits with 18mm wrist pins? I've found MTC kit and JE kit, is there any significant differences between these two other than price? Or any other manufacturers to consider? This is going to be NA build so pistons suited for this application.

[Villeboi]

Small progress with the bike. Installed new cam chain tensioner as the original was starting to show some wear. I had to drill the hole bigger on the tensioner as it wasn't moving freely when the pin was installed.

Also ordered new pistons so when they arrive I can take the cylinders to be rebored and top surface decked.

 

[Villeboi]

Took the engine cases showering with me, nice and clean now. Probably gonna just leave them bare aluminium as I'm not huge fan of cleaning and keeping this kind of things super clean and I think this suits the bike better.

I also got new timing chain and new front timing chain guide as the old one was cracked in few spots.

Need to prepare myself mentally to assemble the engine at some point. May have to do it in my livingroom as I don't have any better place to do it.

[Villeboi]

These came today. MTC 77mm piston kit with teflon buttons. Not sure about the head gasket but it came with the kit. I've read that copper is sometimes tricky to get to seal properly. 

Also cleaned the main oil gallery on the engine block and noticed that this oil nozzle was bit loose. Need to buy some super tiny new o-ring for it as the old one is quite flattened out.

[Gixer1460]

The HG will seal for a bit if you use Gaskacinch or similar but unless the block is wired it will leak eventually - sorry!

Best get a Cosmetic MLS gasket for reliable long term solution.

Edited November 19 by Gixer1460

[Villeboi]

Okay that's what I was thinking too. I think the listing on SPS site showed different type of Cometic gasket but maybe it was just some generic illustration picture only.

Can I use 79mm head gasket with this 77mm bore? Found that Cometic has 79mm head gaskets and in some listings it says that it fits 77-79mm bore.

 

Edited November 20 by Villeboi

[Villeboi]

New 79mm bore Cometic MLS head gasket accuired.

Also got some Suzuki literature. Service manual and original parts catalogue with part numbers and exploded pictures.