splitting open my 82' 1100

[Steve83]

For what it's worth, the oil pump drive sprocket needs to be removed before the case is split.

 

[jerseydogg]

Thanks steve83, I'll remove it tomorrow, prior to splitting the case

 

[zman]

We had a discussion on this or another forum about the mark around on the clutch basket, found it was just a factory grinding mark where they removed a casting ridge.

 

[jerseydogg]

Just ordered a full gasket set that should be here Friday!!!! I'm on my way to riding this weekend, right? NOPE, WHY, because I also ordered a new stator and rectifier and didn't pay attention to the mailing address and sent them to my address in Louisiana instead of NJ (were the bike is).... Oh well, I'll get most of it back together by Saturday.

 

[jerseydogg]

https://youtu.be/8wo2ZHblwyo

OK, I've opened the case (I have 2 short videos of this). All but 2 teeth were shredded off of the stator drive shaft gear..... I don't know what the gear is really called, that's the name that I have assigned to it. All of the teeth are located it one spot. Very little shavings.

I'm looking forward to everyone's feed back and suggestions.

[video]https://youtu.be/8wo2ZHblwyo[/video]

 

[jerseydogg]

https://youtu.be/sIjOc5o-K9w

This is the second video of my gl1100 case split. It is very clean. For a 33 year old bike, I find it incredible clean..keeping in mind that I'm never seen the inside of any motorcycle engine before this one. My plan is to just clean out both cases, change the busted gear and put it back together as soon as the gasket set get here. I'm going with a new stator and I was thinking about putting in new clutch just because it's out.

The sleeve/cylinder walls are very nice. No scratches, grooves or pits.... It's hard to believe that this engine has never been opened.

I'm definitely looking forward to hearing what everyone has to say....

I'm just waiting on gasket/o ring kit and stator to get here....

[video]https://youtu.be/sIjOc5o-K9w[/video]

 

[mcgovern61]

Rodney, did I give you the one from the '81? I know I gave you the one from the '82.

 

[jerseydogg]

Yes, I have both. The 81 and chain is off the block and the 82 is still bolted to the block

 

[dan filipi]

Well I don't know what would have caused them to shear off, very unusual but look at all the other gears and chain close for any damage.

 

[jerseydogg]

Awww man.... Dan, that was going to be my next question. What could have cause this? Ok. I know a few things that I did wrong in the 4-5 weeks that I rode the bike.

1. I hit the starter while the bike was already running, I only did this once.
2. a few times I rested my left foot on the shift pedal, while rolling between 40-50mph, grinded the gears.
3. I'm almost positive that the clutch was WAY out of adjustment, bike would roll slightly with clutch pulled all the way in.

That's on things that I know that I did.

 

[dan filipi]

None of that would cause this that I know of.
I would expect almost certainly there is going to be some damage to other gears or the chain from teeth letting go and getting jambed in between, jamming up could be what took out the other teeth.
Maybe could have been like one tooth broke then a dominoe effect took out the rest.

 

[zman]

I wonder if the chain slapping around for a long time might have caused it?, isn't there a tensioner in there too or is that another chain..

 

[Steve83]

The stripped gear is in direct mesh with the crankshaft gear - not related to the primary chain at all. It drives the alternator rotor, and is driven by the starter. Check the crank gear very carefully! Any chipped or cracked teeth will probably cause this to happen again!

Be sure to clean the oil pickup screen as well! Carefully inspect all the transmission gears, especially the sliding gears - teeth and engaging pins on the sides.

 

[jerseydogg]

ok steve83,

if that gear is driven by the start, then I would assume that I cause the damage when I hit the starter when the bike was already running. check out the video of what I found.

https://youtu.be/4rfONm4Zn5A

Now at the least I need main bearings....

I didn't think that I'd be doing a total rebuild, but with everything that I have to do now, I would say it's as close to a total rebuild as it gets...

[video]https://youtu.be/4rfONm4Zn5A[/video]

 

[jerseydogg]

Does any one want to suggest where to get the main bearing (crank) from. I want to try to have them in NJ by Friday......might be tough but I'd want to be wrenching on the BLUE GOOSE this weekend.

 

[zman]

Bearing are impossible to find, can you measure the journals and re use them?..keep your rod bearings with the appropriate rods and crank bearings with the journals. Mixing them up can be trouble.

 

[jerseydogg]

OK, I'll be reusing what I have. I'll have to measure them when I take them off the old crank. I'm confidence that they will be reusable because the inside of this motor is super clean.....although something cause the problem in the first place.

Zman, thanks I definitely will keep everything in its same position.. I'll be on this tomorrow....

I guess I'll be headed to get a micrometer (mine is in Louisiana)........

It's on!!!!!!

 

[dan filipi]

Cost and time finding bearings (if possible) makes a used engine much cheaper.
I'd check the color codes and condition of the bearings you have. May get lucky and it all matches up.

 

[zman]

jerseydogg » Wed Apr 15, 2015 3:52 pm[/url]":j0rpx6bc]
OK, I'll be reusing what I have. I'll have to measure them when I take them off the old crank. I'm confidence that they will be reusable because the inside of this motor is super clean.....although something cause the problem in the first place.

Zman, thanks I definitely will keep everything in its same position.. I'll be on this tomorrow....

I guess I'll be headed to get a micrometer (mine is in Louisiana)........

It's on!!!!!!

Just need to be sure, I doubt there is any difference but your there and it should be done so there are no surprises.

 

[slabghost]

Once a project starts. The scariest words to hear are "while we're at it".