Mechanical/restoration supervision sought

**terbang** · 20th April 2007, 09:49

If it were an 1100 I would give it a light hone out to the 4 thou limit and even a bit more if you have too and chuck it back together with a new set of rings (and piston pin clips for peace of mind). There are allways vertical scores on those bores that should easily hone out but if they are deep enough for the hone to not work then its a rebore or resleeve (which can be done to these things)... She will easily do another 20000 kays like that while you look for a decent oversize kit. Its only gaskets that you will waste later when you do fit your big bore kit... Those GS engines will run fine way out on the bore to piston tolerances as long as your ring groves are good. I'm running one now that I assembled at 4 thou limit and Its running just fine. Don't get too agressive with the hone and use a fine stone. Too much honing will give you excesive 2nd ring wear. Assmble them with only light oil (I use ATF) on the bores.
Resleeving is worth a look as long as your piston ring groves are good or, and in my view the best option, a big bore kit from Wiseco.

**psyguy** · 20th April 2007, 09:52

Originally Posted by terbang

If it were an 1100 I would ...

thanks terbang
i'm getting a good picture of my options now and things no longer look as grim

**psyguy** · 20th April 2007, 12:52

alpha-sports offered to exchange my 1.0 pistons for 0.5 (yes, they recon they have all 4 of them)
but the rings are no longer available in 0.5...

they suggested that "the 1.0 rings are easily resized to 0.5"

can someone please comment on this, like what it takes to do it, who can do it, at what sort of price, is this really the way to go, etc?

many thanks again

**psyguy** · 20th April 2007, 12:57

Originally Posted by terbang

... Resleeving is worth a look as long as your piston ring groves are good or, and in my view the best option, a big bore kit from Wiseco.

what big bore kit from wiseco do you have in mind?
i couldn't find anything from them for 850 and the next size up -1000 - the pistons have bigger gudgeon pin (as far as i'm informed)

**Ixion** · 20th April 2007, 13:09

Originally Posted by psyguy

alpha-sports offered to exchange my 1.0 pistons for 0.5 (yes, they recon they have all 4 of them)
but the rings are no longer available in 0.5...

they suggested that "the 1.0 rings are easily resized to 0.5"

can someone please comment on this, like what it takes to do it, who can do it, at what sort of price, is this really the way to go, etc?

many thanks again

I've done this in the past. Basically you just carefully file a few thou off the rings ends, to get the gap correct. However it certainly couldn't be described as standard practice.

However, unless they are "special" rings (stepped, keystone , or whatever), rings are a pretty standard thing. Try taking an existing piston into one of the big reconditioners, and explaining that you need "these type riungs, but for +20 thou larger". If they can't help directly , ask if they'll tell you where they get their rings from. Also there are companies that specialise in piston rings. Google "piston rings"

**psyguy** · 24th April 2007, 19:15

while on the quest for those pistons, i wasn't quite idle in the other departments either

the engine bottom is now back in frame
the valves back in the head, all carefully grinded, fitted with NEW springs
the head mating surface planed, apparently was 8 thou out (had this done by some nice guys at "west auckland reconditioners" - they have a garage full of american v8 cars, so you don't mind going there or having to wait )

i also went to DODGYITI's to check out that mean guzzi he's doing up, looks very promissing!

went to CLASSIC Z's garage to have some spark plug thread inserts fitted (visible on the photo below) so no more worries with worn threads
had a chance to check out his latest project - (if i'm not mistaken) a turbo injected z1300

! can't wait to see the progress there

cheers everyone

**psyguy** · 24th April 2007, 19:23

a question here for those good people that help me out whenever i need it

is there any reason why not to proceed with checking/adjusting valve shims while the head is off?

(there isn't anything else i need to do right now, so i thought i could do these adjustments - and order new shims if needed)

also, can i do without the original valve spring depressing tool?!

any other tips?

thanks!

**psyguy** · 24th April 2007, 19:33

having exchanged dozens and dozens of emails with bike parts places i think finally i might have the last two pistons on their way!

anderson-vintage-parts first said they didn't have them but now they recon they do, so i ordered some, and will see how it goes...

also had a guy in singapore! (off ebay) tell me he had some but they turned out to be pistons for a gs425
interestingly, the 13 digit part number was nearly the same:
gs850: 12111-45100-100
gs425: 12111-45110-100

**Ixion** · 24th April 2007, 19:47

OHC engine, usually no reason why you can't set the valve clearance on the bench. Only issue may be if they have to be set at a certain position, but that's rare, usually it's just on the rock.

**psyguy** · 24th April 2007, 20:08

Originally Posted by Ixion

OHC engine, usually no reason why you can't set the valve clearance on the bench. Only issue may be if they have to be set at a certain position, but that's rare, usually it's just on the rock.

what's "on the rock"?
the service manual suggests the clearances have to be checked with the cam lobe away from the shim (if that's what you mean?)
thanks

**Ixion** · 24th April 2007, 21:15

Yep. with the cam turned so that both valves are fully closed (well, all 4 on a 4 valver) .

How did you find dealing with Tad ? I think I'm going to need something from him. When he first started AVP report was he was really good, helpful and on the ball. Then he had a period when he had some personal problems, and the business sort of got away on him , and some people were pretty unhappy.

Lately reports are that he's got it back together again. But I see he's had some sort of big falling out just the other week with the two stroke 'zuki guys. Dunno what about, nobody's talking about it.

**psyguy** · 24th April 2007, 21:41

Originally Posted by Ixion

How did you find dealing with Tad ?

uh, sorry, who's tad / avp ?

**Ixion** · 24th April 2007, 21:54

Tad Anderson. Anderson Vintage Parts. You said you were getting your pistons from him ?

**psyguy** · 24th April 2007, 22:37

Originally Posted by Ixion

Tad Anderson. Anderson Vintage Parts. You said you were getting your pistons from him ?

oh, yes.. as i said - they first said they didn't have the pistons, then i said that their website suggests they have them in stock, then they said they actually have them...

then i went to order some and the shipping came up to us $170!
so i complained
and they adjusted the shipping to us$50

as per their prices, i find them somewhat more expensive (in their website price listings) than say alpha-sports or bike-bandit, but these other guys add some "tax" at the end of your purchase so i think it equals out

so, not sure what to tell you... perhaps to double check the availability of all the parts you need and check for the accurate postage before pushing the "buy" button?

also, sometimes they answered my email quickly, sometimes they didn't

i don't know what you're after but i find z-enterprises one of my favourite websites and best prices too. they don't have such a large offer though.

anyhow, i try to stay away from places in the uk as their prices often match those in the us, but are in british pounds! so can be 50-80% dearer!

**Ixion** · 24th April 2007, 22:46

Hm. sounds like he still hasn't quite got it together. He's a really nice guy(well, insofar as one can tell of a person one has only "met" online), but not the brightest star in the sky, and not too good at the administrative stuff.

Guess I'll try him and see. Thanks for the heads up about postage I'll make sure I get a quote from him first.

Know what you mean about UK. Only thing is. sometimes their postage can be a LOT cheaper than the US. Which if it's a cheap but heavy item can make a difference.