noise behind clutch cover

[twalter]

And if it does "shake around"? Oh my god!! Don't hurt me here.

[Geezer]

A little wiggle is OK but if it moves 1/4" or more, the main shaft bearing is history.

Geezer

[andreashweiss]

Figure out what is worn out and send me an e-mail I will most likely have those parts in my misc clutch/trans pile andreashweiss@yahoo.com

[twalter]

I got it appart. Shavings in oil. Everything is showing signs of neglect. My guess is that the PO sunofa*%$^**(% tried to make it good enough for a test ride then looked for me.....the sucker. All of the gears on the countershaft are very loose. Some gears are new some are old. The noise was the dogs on the third gear from the left running into the slots of the second gear from the left. So......since the hivo chain is very loose and looks like it has very sharp teeth, and the motor has been fed metal, I am in the market for a replacement. Any suggestions?

[knewsom]

Contact andreas - last I checked, he had a whole replacement engine and transmission - if not, I just saw a couple on ebay..? I'll also keep my eyes out for parts bikes as well.

good luck man... sorry to hear the news.

-Kris

[andreashweiss]

Sorry to here the bad news. I do have a low mileage 1981 xs1100 bottom end. Complete with transmission,crank and connecting rods/pistons/rings. You would need all your engine covers ,clutch.pickup coils jugs,head,middle gear,starter etc. Mileage was approx 20,000 miles. Weighes 125 pounds. Cost $125.00 plus shipping. Already have it in a rubbermaid container which UPS will take. Add $20.00 for container plus UPS cost to you.andreashweiss@yahoo.com

[twalter]

So... I got a bottom end from AW. It looks good. I am about to tear into my top end to see if I got stuff I can use. I'll let ya'll know of my adventures. I am sure this will be worth it. I am sure this will be worth it. I am sure this will be worth it. Oh..... sorry, therapy.

[Geezer]

Are there any XSives in your area that can offer you hand. I'm too far away to help.

Swapping the top end and middle drive should be an easy weekend project leaving installing the engine for the next weekend.

Geezer

[twalter]

Can a guy just put this stuff together if his jugs are within spec? Do you have to hone the cylinders to get the new/used rings to seat?

[DiverRay]

I would LIGHTLY hone the cylinders, just to help with the rings. I would also make SURE there is no ridge at the top of the jugs, so the top ring doesn't break.
Ray

[Geezer]

DO NOT HONE THE CYLINDERS unless you're installing new (not new to you but brand new) piston rings. All it will do is make the bike smoke and wear out the rings faster.

Clean the tops of the pistons before pulling the cylinders off and number the pistons so you can be sure and get them back in the correct bores.

I would try pulling the pistons out only far enough to remove the piston pins to save the work of recompressing the rings. This will take another set of hands helping you or the cylinder block can get away from you pretty quickly.

If it were my bike, I'd use gasket remover to help clean the mating surfaces and then just move the parts over. Assuming the parts you're using from the old engine are goog, clean them up and move them over with a new set of gaskets. Don't forget new piston pin clips.

Geezer

[DiverRay]

Geezer,
I did say LIGHTLY, because I thought he was going to put the rings pistons into a different set of jugs. If he just swaps jugs, pistons and all, then I agree, DO NOT hone. The rings have already worn into the jugs, and should be good to go.
Ray

[Geezer]

I wasn't PO'ed about it, I used all caps to be sure and get the point across that I was serious about this. DO NOT SEEK THE TREASURE, oops, wrong movie... ;o)

Geezer

[twalter]

Thanks for the input guys. I guess I did not fully explain what I am trying to do here. The bottom I got from Andreas still has the pistons and rings hanging on the rods. I am assuming that they are in better shape than the ones I have (it was smokin'--90# compression). So my thought was to use my jugs IF they are in specs and not trashed. If they are to far gone, it will be a 1179cc deal. Then my original question won't matter. It sure is a nice day for a ride and my scooter's busted.........dang!

[Geezer]

If you were going to try using the other pistons and rings you'd need to measure the clearance in the bores first. Remove the pistons and rings from the new bottom end and then carefully remove the rings from the pistons.

When you have the jugs off the old engine clean them up and check for a ridge near the top of the cylinders. If there's a ridge, you have to use the original rings as they're worn to the ridge.

If there isn't a ridge put the rings one at a time into a cylinder to check the end gap with a feeler gage. Use a piston as a plunger to get the ring square in the bore near the top. There will be a small variance between the cylinders so you will have to find which piston and rings fit best where. And yes hone the cylinders. Also if the end gap from the new to you rings isn't significantly better than the old rings, use the ones that you had.

There's a good chance the rings will wear out faster than normal but by that time you could have saved up for a big bore kit.

Geezer