We're Going In Deep! Spline Lube, Custom Powder Coating, Ect. PICS.

[Hodakaguy]

My Friends R1100GS blew a head gasket a few weeks ago while out on a ride. 36,000 miles on the clock. We decided that as long as we have to go into the head area that we should do some custom powder coating as well. (More on that to come as the work progesses...Top secret stuff ya know ). Sooooo, that opened the large can of worms and we were off and running.



A little improvised ramp is in order. Way better than your hands and knees. It's going to look a LOT different when it rolls back down off the stand. (insert joke here about falling off stand)




Pulled the heads and cylinders. The bores looked just like new! His bike has been making a knocking sound at idle coming from the front cam chain tensioner so we decided to pull the cover and change it while we're doing the work. You'll see lots of bits and pieces pulled off the bike that normally wouldn't be done during a job like this, We have a lot of powder coating to do ahead of us. (He got a great deal on a powder coating setup so we are going to have some fun!)




The rear of the bike has had some vibrations lately that we didn't like. So we decided to pull the drive line and inspect it while we have the bike apart. Here's a shot with the final drive removed and looking into the swing arm with the drive line installed still. Splines here look great.




Here we removed the swing arm and we're removing the drive line from the transmission output splines. It just pops off twords the rear with a little pressure. Fun Stuff.




Well the Drive line is out.....But were so close we should also pull the trans and inspect/lube the transmission splines. Here we are getting ready to pull the transmission. Lots of wires to unhook ect. Looks a lot worse than it really is though. Getting the air box out is a tight squeeze.




Transmission out and on the table. Notice no front suspension components....Hmmmm. Powdercoat....




Poor GS. I think this is the point I offered to buy the wheels from his bike......Come on man, you'll never need them again.




The splines were very dry but in excellent cond. There is a small leak on the transmission input seal though, you can see the oil that has been seeping out and running down the case. Another item to add to the growing list of needed seals and parts.




Splines on the clutch side. Look good.




A better view of the oil leak coming from the input seal on the trans.




Another angle of the trans removed.




This is a shot of the transmission output shaft. You can see a small leak with some trans fluid puddled up under the output splines. You can also see a wet area on the clutch rubber boot. More seals to order.




Here's the clutch disk. Getting pretty close to the rivets. Anyone know what the depth to the rivets is on a new clutch? Time to get a new one on order.......Man, this list is getting bigger quick!




The tapered roller bearings on the final drive were pretty nasty, the one on the other side was the worst. The grease looked brown, like some moisture might have got to them in the past. You could see some slight wear on the races of the bearings. We will replace these bearings as well as the ones in the swing arm.


More pictures to come as the work progresses. Lots of fun ahead.

Thought you might like a look.

Hodakaguy

[Hootowl]

I'm not seeing any photo's

[Hodakaguy]

lets try this....Hopefully the pics are working now.

Hodakaguy

[JimVonBaden]

Nice!

Looks like you need a new clutch disc, if nothing else because, at least in the picture, your splines looked a little too worn, and the plate is also worn pretty good.

Keep us informed, and great pictures!

Jim

PS I would tie your centerstand to your front wheel just to be sure. I see the bike hanging, but it can't hurt.

[Gadget Boy]

It's quite the adventure you've started here....

[btretired]

Excellent pictures and description-- but unless this picture is flipped please hang your flag correctly..

Thanks-- BT


http://www.ushistory.org/betsy/flagetiq.html

[NBeener]

Great pictorial. You guys ... got some stones, I'll give you that

Next time ... for the record ... I'll give you a couple of intersections in L.A. You just park the bike there. They can tear it down MUCH faster than you guys did

Best of luck on the fix-up and re-assembly.

[stuckinmud]

Oops, I had no idea. Sorry about that. I will take care of it promptly. Thank you for the heads up.

[YetiGS]

Wow! Quite the project you got going there! Good luck and I look forward to seeing how it turns out!

[btretired]

Carry On!!

Originally Posted by stuckinmud

Oops, I had no idea. Sorry about that. I will take care of it promptly. Thank you for the heads up.

[Hodakaguy]

Originally Posted by JimVonBaden

Nice!

Looks like you need a new clutch disc, if nothing else because, at least in the picture, your splines looked a little too worn, and the plate is also worn pretty good.

Keep us informed, and great pictures!

Jim

PS I would tie your centerstand to your front wheel just to be sure. I see the bike hanging, but it can't hurt.

Actually the splines looked really good, probably just the angle of the pic. The Disk is pretty worn though, a new one will be ordered and installed. You know how these projects are......."Man, while we have it apart we should replace that also, and that....and, yep that to." And we really don't need to take that apart but it sure would look good powdercoated

[R3B]

Originally Posted by Hodakaguy

Thought you might like a look.

Nice pictures, but why ripp it apart as it's not even through its breaking in period ??? :-)

[stuckinmud]

Originally Posted by JimVonBaden

PS I would tie your centerstand to your front wheel just to be sure. I see the bike hanging, but it can't hurt.

Yes, that is a good idea. But take a good look the front forks they are just hanging there as well. The front swing arm has been bead blasted and is ready for paint. Hodakaguy plans to get some pics of the preped parts up soon.

[Hodakaguy]

Originally Posted by R3B

Nice pictures, but why ripp it apart as it's not even through its breaking in period ??? :-)

I know what you mean, but...

We had to pull a head to do the blown head gasket. The front cam chain tensioner was making a lot of noise at idle so we had to take the front cover apart to get to it. The drive line was showing signs of high vibration so it needed to be looked at and since we were so close with the drive line out figured we should look at the clutch splines while we were there. (The clutch had quite a bit of wear so its probably good we looked into it). The seal on the transmission input shaft also ended up needing some attention.

There are a lot of items that didn't need to come apart (Like the front suspension parts, cylinders, ect) but we have a lot of custom powdercoating we want to do so they had to come off as well. I didn't show any pictures yet of the heads stripped (valves out ect) getting ready to be cleaned and coated. We created a lot of work for ourselves wanting to get the powdercoating done.

Pretty fun stuff though! And its winter....Gotta do something while its cold and wet out side

Hodakaguy

[gonzomup]

Originally Posted by Hodakaguy

My Friends R1100GS blew a head gasket a few weeks ago while out on a ride. 36,000 miles on the clock.

Great pics and story! I'm doing a lot of the same thing right now.

One question, though -- Is anyone else wondering or concerned about the fact that the head gasket blew at "only" 36k miles? That just seems awfully young to me, but I know I don't know all of the reasons a head could blow. Maybe just a simple defect in the gasket?

Good luck with the work! Kinda nice that you're a bit ahead of me so I'll know what's coming!

Bohdan