Rebuilding Junior - died and LIVES AGAIN!

[codajastal]

I am jealous of nearly every GS I see on this site.

lol welcome to my world

[BockinBboy]

Junior is a '92, which had white rims stock; however, they are a stock color of rims offered on 96-00 (maybe some other years to) models.

BTW I should let you know, adidasguy, that it is a compliment that stats about your bikes occupy some of my brain space like this.

- Bboy

[adidasguy]

Finally cracked open that engine. What a muthirfooker. I guess I should have removed parts in a different order. I ended up cutting off the clutch assembly bolt (thank you Harbor Freight grinder). Then could remove the piece that kept the case from opening up.

Interesting what damage was done. The gear of the counter balancer was grinding away the inside of the case.
Was able to salvage the crank shaft for a member. Tranny parts are all good. So I'll probably bag & tag them then recycle the remaining carcass for a few dollars.

[jmill]

It's amazing that Junior was running at all, looking at how much wear was occurring. That's a serious chunk taken out of the casing!

[jacob92icu]

I don't know if this is the case with the counter balance weights on the crankshaft in your situation but sometimes manufacturers will machine clearances in the surface of the engine cases in random spots just because of manufacture differences.

[adidasguy]

No - this really was the gear grinding out the case. The metal shavings in the oil sump were proof. Combined with a bad counter balance bearing on that end --- it really happened.

(.....and notice the metal shavings in the lower photo.)

[Gorilla]

dang i read this entire post and all the videos...NOW THAT IS A LOT OF WORK!

[adidasguy]

Having a few friends to help  and all the necessary tools on hand made it really go pretty easy. also having spare engine parts around helped, too.
It was quite a learning experience and couldn't have done it without bluesmudge and jmill.

[Gorilla]

I hope to gain as much experience and insight as all of you 

[jmill]

It's looking over things like this that make me want to keep the my GS... I have sellers regret and I haven't even sold it yet! Ahhhhhh