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 Post subject: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#1  Unread postPosted: July 27th, 2017, 10:58 am

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Location: Mantua, New Jersey
Local time: December 13th, 2017, 7:41 pm
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My Rides: Restored '82 Standard GL1100 (with '83 engine) Hondaline bags.
'81 GL1100 - Gave up the ghost to give life to the '82!
1st bike '81 Suzuki GN400

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For my '82 1100 Standard, my current starter is working like a champ. BUT, you never know how long it will last (currently pushing 35 years). The engine is actually an '83 and it only had 53K miles on it when installed into my bike. I have read many stories on here about hot engines and slow starters with the slow starter being either bad connection or worn out starter.

I have 2 spare starters lying around. One is the original starter that was in our '82 engine which only had 23K miles on it (but sat out in the weather for 12 years rusting) and the leftover '81 starter from the '81 diesel (sounding) knocking engine. The '81 engine had well over 167k miles before being pulled so I thought it fair to assume everything was original.

The '82 starter turns very slow and heats up when I put battery power to it. The '81 starter spins quicker, but I have no idea of the internal condition. Knowing the '82 unit needs work, I decided the '81 starter was the better candidate for a renewal project.

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 Post subject: Re: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#2  Unread postPosted: July 27th, 2017, 11:01 am

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Location: Mantua, New Jersey
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My Rides: Restored '82 Standard GL1100 (with '83 engine) Hondaline bags.
'81 GL1100 - Gave up the ghost to give life to the '82!
1st bike '81 Suzuki GN400

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Start off with a basic 1100 starter:

Image

Simple enough since it is off the bike and sitting on a shelf. :hihihi:

Way back in the wire harness project, I came across an 1100 starter rebuild kit that was on sale and seemed to have everything.

Image

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 Post subject: Re: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#3  Unread postPosted: July 27th, 2017, 11:38 am

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Location: Mantua, New Jersey
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My Rides: Restored '82 Standard GL1100 (with '83 engine) Hondaline bags.
'81 GL1100 - Gave up the ghost to give life to the '82!
1st bike '81 Suzuki GN400

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First step is to remove the 3 long bolts holding the case together. Next, separate the ends.

Image

Lots of carbon in this end:

Image

A bit dirty, but the grease was still pliable:

Image

A good look at the brushes and I am under the opinion this starter may already have been rebuilt in the past or at least got new brushes.

Image

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 Post subject: Re: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#4  Unread postPosted: July 27th, 2017, 11:45 am

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Location: Mantua, New Jersey
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My Rides: Restored '82 Standard GL1100 (with '83 engine) Hondaline bags.
'81 GL1100 - Gave up the ghost to give life to the '82!
1st bike '81 Suzuki GN400

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I opened up the '82 starter to compare and it also had good brushes. Of course, the '82 starter only had 23K mile on it.

Start cleaning!

Image

Getting the drive end out was a bit tricky! The unit needs to be driven out of the gear housing, but the plate on the end that holds the smaller gears is on the same plane as the face of the housing. Not having a work bench or a vice presented real issues getting this out! I had to lay the housing across a piece of wood while tapping down on the shaft. It was a pain, but I got it.

Image

The next big issue was getting that bearing off! No bearing puller here so a good old fashioned wedge system was used behind the bearing while I worked it up the shaft (not for the faint of heart!). For those that attempt to change out this bearing, be aware that you do not scratch the shaft! :shock:

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 Post subject: Re: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#5  Unread postPosted: July 27th, 2017, 11:49 am

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Location: Mantua, New Jersey
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My Rides: Restored '82 Standard GL1100 (with '83 engine) Hondaline bags.
'81 GL1100 - Gave up the ghost to give life to the '82!
1st bike '81 Suzuki GN400

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To pull the main rotor out, you have to gently (and I mean gently!) pull the main wire back enough to push the unit out. Clean up with electrical cleaner and steel wool. Shot with electrical cleaner again and I went over it with a magnet to be sure no steel wool particles remain.

Image

Image

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 Post subject: Re: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#6  Unread postPosted: July 27th, 2017, 11:56 am

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Location: Mantua, New Jersey
Local time: December 13th, 2017, 7:41 pm
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My Rides: Restored '82 Standard GL1100 (with '83 engine) Hondaline bags.
'81 GL1100 - Gave up the ghost to give life to the '82!
1st bike '81 Suzuki GN400

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Bearings, seals and bushings out, new bearings seal and bushing in!

Image

Referring back to this picture, see that bushing in the housing end? I have no puller and anything else will damage the housing if I pry to hard.

Image

On YouTube, I saw a trick where you can use hydraulic pressure to remove the bushing! :shock: YEP!

First, fill the cavity with grease:

Image

Then, find a bolt or shaft that is the same size as the inside diameter of the bushing. Next, tap that unit it and it will seal the bushing while pushing the grease under the bushing, hence, forcing the bushing out!

Image

Yep, it works!! :yahoo:

Image

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 Post subject: Re: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#7  Unread postPosted: July 27th, 2017, 12:01 pm

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Location: Mantua, New Jersey
Local time: December 13th, 2017, 7:41 pm
Country:  United States (us)
My Rides: Restored '82 Standard GL1100 (with '83 engine) Hondaline bags.
'81 GL1100 - Gave up the ghost to give life to the '82!
1st bike '81 Suzuki GN400

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Following the kit and the parts as laid out on the table, I greased the bearings, greased the spline, replaced the bushings on both ends, replaced both drive gear bearings, new brush plate and brushes, new gaskets on the end plate for the drive end, new o-rings on the end caps as well as the drive end that fits into the engine.

Spun the unit by hand first (have to use pliers, it does not turn easy nor should it). Ran test leads from the battery and that sucker spun right up!! :yahoo: :party:

Now clean up and perhaps paint to match the Iron color, but otherwise I have a newly rebuilt starter ready for install at a moments notice! :yes:

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 Post subject: Re: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#8  Unread postPosted: July 27th, 2017, 12:54 pm

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Nice write up. I really like that grease trick getting that bushing out.

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 Post subject: Re: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#9  Unread postPosted: July 27th, 2017, 1:44 pm

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Excellent write up. As slabghost mentions, like the grease trick for the bushing.

Bike must be working well - you're looking for projects to do!! :music:

Did you finish the wiring project you were working on?

Cheers

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 Post subject: Re: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#10  Unread postPosted: July 27th, 2017, 3:07 pm

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Nice writeup, thanks for the grease tip.

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 Post subject: Re: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#11  Unread postPosted: July 27th, 2017, 3:14 pm

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Well done!

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 Post subject: Re: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#12  Unread postPosted: July 27th, 2017, 5:40 pm

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Gee nice thread .....

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 Post subject: Re: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#13  Unread postPosted: July 29th, 2017, 5:24 pm

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Joined: December 3rd, 2009, 4:20 pm
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Location: Mantua, New Jersey
Local time: December 13th, 2017, 7:41 pm
Country:  United States (us)
My Rides: Restored '82 Standard GL1100 (with '83 engine) Hondaline bags.
'81 GL1100 - Gave up the ghost to give life to the '82!
1st bike '81 Suzuki GN400

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After re-reading the thread, I feel bad that I did not take more pictures for each step. Having the '82 starter also available, I broke it down for some more shots. Granted, it is not cleaned yet, but should help with the visual process. So here are pictures of some of the process. I mentioned early on about moving the main wire out of the way to pull the rotor, here are some pics of how that looks.

Here you can see how the wire blocks the front of the rotor:

Image

Gently bend the wire back a bit. Just enough to get the rotor out:

Image

Rotor sliding out:

Image

One more end view so the uninitiated have a good idea what it should look like when pulling the rotor. It is real tight!

Image

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 Post subject: Re: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#14  Unread postPosted: July 29th, 2017, 5:28 pm

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My Rides: Restored '82 Standard GL1100 (with '83 engine) Hondaline bags.
'81 GL1100 - Gave up the ghost to give life to the '82!
1st bike '81 Suzuki GN400

Profile Personal album

My YouTube Channel
With the rotor out, turn the case around to the other end (gear end) and you should see a large gasket in place (which was behind the plate). Be sure to remove and replace this gasket. No sealant needed on it. On the other side of the plate is another gasket that is the full outside diameter, but has a larger inside diameter. Both gasket should be in the kit.

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 Post subject: Re: 1100 Starter Rebuild
Share Post: Share on FacebookShare on TwitterShare on TumblrShare on Google+Share on MySpace  Post Number:#15  Unread postPosted: July 29th, 2017, 5:35 pm

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Nice to see a well written "how to do it"

Nice job.

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