Broken GS engine: here we start with the works

[simon79]

Keep it up man!
These pics are top quality stuff. We want more!
And, nice bike too.

Ottimo lavoro e buon proseguimento

[GenTLe]

You've got some access to a lot of high dollar and really nice stuff there, like that fancy runout gauge. 

Well, not really: after USSR crushed in 1991, a lot of guys from east republics like Poland came here in west Europe (Italy too) to sell a lot of their instruments. For example I paid that gauge about 15€ (about 20$), or a Polish micrometer 50-75mm (0,01mm scale) something like 25$ (and it's from the best instrumentation and guns company of Poland). And I can guarantee that Russian stuff is very very good, nothing to share, for example, with Chinese production  
Plus: now the Uk£ is in parity with Eur, and I'm buying these tools from UK sellers through eBay: the last one is a Mitutoyo (most probably the best instrumentation brand in the world) 0 to 25mm (0.001mm scale) micrometer, and I had it for 30Eur (=41US$), expedition comprise  

Bye, Alex

[GenTLe]

I had somehow to pass this Sunday, so I went on with the job 

This is the engine without clutch cover (previously I removed the ignition sensor):


The cogs are perfect:


Then, thanks to my air impact gun, I removed the clutch:


The clutch plates are very good too:


The clutch side without it and without oil pump and some other stuff related to the gears:


On the other side, I took away the power generator:


This bloody gasket was near to really drive me crazy!!!!!!! It took me 1,5 hour to remove it!!!! 



One of the coils lost part of its resin covering... But I think it's ok in this way too (or maybe I'll rebuild it with some special resin, let's see):


Let's remove the starter engine...


...and the oil pan:


The oil pan cover was quite dirty: it's the place where all the most dirty parts of the oil settles.
Now it looks good:


Good! The engine now is ready to be really opened!


And the 2 shells are just un-glued:


But now STOP, otherwise the old bike owner (who made me to promise to call him when I had open the engine) will kill me

See you!

[BeerGarage]

Oh, the suspense.  Better than any mystery novel.

[coll0412]

It is hard to tell in the picture but it looks like the epoxy on one of the magnets has come off. Typically that is an indication that the magnet on the rotor is about to come loose. If that happens it can come off and break apart to spread itself all around your engine. Another picture may help, but in the one above it appears that way.

Good Luck Though!

[GenTLe]

Hi Coll0412,
yes, it's true: a small piece of resin came away, but it wasn't because the rotor is loose. It's very well tighten. It's only a matter of un-glueing (it remained in my hand only touching it):
 

Thanks for the warning!

[yamahonkawazuki]

TBH id replace it

[sledge]

Difficult to say with certainty from the pic but from looking at the end of the Balancer shaft it would appear there is some heat discolouration or "Blueing" present. It could be down to the process used to harden the shaft  but it could also indicate a dry/worn/overheated bearing. I guess all will be revealed when you split the cases 

All the bearing shells in the GS5 are colour-coded. They have a tiny spot of paint on one edge which indicates their size. Try not to loose this spot if you clean them, it makes ordering replacements far easier. Chances are they wont all be the same size and they are not interchangable so its important to make a note of which size/colour goes in which location otherwise you have to cross-reference the various markings to ID the correct size. I cant remember what colours are used other than green and yellow and I dont have the manual with me right now.

I have to say your photos are setting a good example and show exactly how an engine should be dismantled and how the individual components should inspected and assesed  I wouldnt worry to much about the missing epoxy on the magnet. Almost every rotor I have seen has been like that and had some missing from the front, as long as the magnet is not cracked and there is plenty of epoxy along the sides it will hold.

Possible discolouration indicated.


Very similar to this well shagged example.

[GenTLe]

Difficult to say with certainty from the pic but from looking at the end of the Balancer shaft it would appear there is some heat discolouration or "Blueing" present. It could be down to the process used to harden the shaft  but it could also indicate a dry/worn/overheated bearing. I guess all will be revealed when you split the cases 

I'll see when I'll open the crankcase The original diagnosis was "melted con-rod bearing", but they're fine, so maybe the problem is at balancer shaft level (but I think the problem is at gears level). I've the plastugauge to measure the clearance of the shafts so it will not be a problem.
Yes, I know about the colour code and letters for the bearing sizes 

Ciao, Alex

[The Buddha]

Cam lobe wear is common with motors that have had crank bearings go bad. The metal that disintegrates ends up in the oil and gets to wherever it does ... in bearings you dont notice it especially, its just looks like bad bearings. Cams - yea you see it, yours are not too bad anyway.
Cool.
Buddha.

[commuterdude]

This is so EXCITING!

[ohgood]

This is so EXCITING!

look, cabin fever has taken one soul just now...



i'm kidding, i like the thread too

[kml.krk]

dude! when is the next episode...?
I can't wait 

seriously, this is very addictive 

cheers
Kamil

[GenTLe]

dude! when is the next episode...?

Eheheh, yesterday I opened the engine. I didn't took pictures because the old owner was there. I'll do this evening probably.
But... Nothing special to say: from a first look, this bloody engine has absolutely NOTHING 

So I'll have to check all part dimentions and clearances in order to find what's wrong in it 
Something very very boring...

[ohgood]

dude! when is the next episode...?

Eheheh, yesterday I opened the engine. I didn't took pictures because the old owner was there. I'll do this evening probably.
But... Nothing special to say: from a first look, this bloody engine has absolutely NOTHING 

So I'll have to check all part dimentions and clearances in order to find what's wrong in it 
Something very very boring...

how's bout a podcast ?

so, what were the symptoms causing you to tear it down ? i don't remember reading that part ...

[andyfoxgs500]

very good i almost feel like i could rebuild my engine just with these pic's

[GenTLe]

so, what were the symptoms causing you to tear it down ? i don't remember reading that part ...

Noisy engine, a couple of diagnosis of problems to connecting rods bearings, plus blocked engine while the owner was stuck at traffic lights...
I think some lubrication problem, but I hoped to find a more clear problem

[The Buddha]

Cam chain rattle ? cam shaft side drift ? however that cam lobe did show some weird wear. Maybe it was making some noise.
You dont have the giveaway signs of oil starvation though ... Yea sledge says counterbalancer ... OK I'd give that a maybe ...
Cool.
Buddha.

[GenTLe]

The engine is now finally open and clean 

Let's see some detail.
This is the work table with all the most internal parts of the engine:




The upper part of the crankcase...


...and the lower part:


The gears (upper the primary shaft, lower the secondary one):


The 3 gear "forks":


Ok, let's go deeper in the bearing and surface conditions 

First: the balancer shaft. It looks fine:



Its bearings are not bad too (remind we're speaking about 30000km -18600 miles- used bike):



The cranckshaft looks ok (the surfaces are perfectly smooth, touching them with a nail):



Its bearings could be better but they're not scraped or melted (and again they're smooth, touching them with a nail):


Also con-rod bearings are not that bad (maybe I'll change them, to stay on safe side):



Instead I don't like too much the seat of the secondary gear shaft bearing, the big one next to the final transmission pinion. It is quite smooth, but it looks like if the external part of this bearing rotated in its seat (and it's impossible since it has a stopper to avoid this). I'll put some gasket paste on this surface to act as a soft locker.



See you, and merry Christmas to all

Alex

[xhyperxshogunx]

love the incredible details in the picture..engine look fine to me ..maybe the owner was just hearing stuff