how to rebuild 1100M engine? Idiot's guide

[captain chaos]

Hi,

so I have disassembled my mates 1100M engine, with the intention of checking it and rebuilding it correctly ready for boost.
Crankshaft and connecting rod bearings are like new, camshafts as well, gearbox is in very good condition, basically we want to install Busa pistons and rebuild the thing.
What do you guys recommend:
- cilinder studs of course, APE?
- crankcase bolts (the 12 ones around the crankshaft)
- camchain? DID? Original Suzuki? The current camchain is still in good condition.
- all gaskets and seals and o-rings, original Suzuki?
- head gasket, Cometic? Or something else?
- new piston rings
Anything I forgot?

Thanks.

[katana]

Oct 21, 2014 6:40:52 GMT captain chaos said:

Hi,

so I have disassembled my mates 1100M engine, with the intention of checking it and rebuilding it correctly ready for boost.
Crankshaft and connecting rod bearings are like new, camshafts as well, gearbox is in very good condition, basically we want to install Busa pistons and rebuild the thing.
What do you guys recommend:
- cylinder studs of course, APE? Naturally
- crankcase bolts (the 12 ones around the crankshaft) I would for what they cost!
- camchain? DID? Original Suzuki? The current camchain is still in good condition. Tsbaki is my cam chain of choice
- all gaskets and seals and o-rings, original Suzuki? Pattern gaskets and seals can be very 'hit or miss'. For that reason would tend to go with Suzuki.
- head gasket, Cometic? Or something else? With turbo's i've only ever used copper gaskets for the head and trust them implicitely so can't comment on using a MLS type.
- new piston rings. As either new or s/hand rings will be going into a fresh honed bore both will work but you do need good tension on the rings for a good seal under boost so i'd probably use new out of preference.
Anything I forgot? Little trick is to add or rather remove a window between cylinder liners 1&2 and 3&4 - allows air movement between cylinders below the pistons a bit easier. Under-cut the gear dogs for positive engagement. Add some big crankcase vents.

Thanks.

Personal opinion added in RED above

[captain chaos]

Thanks dude.

The crankcase bolts, do APE make them as well?

Suzuki themselves also make the windows between 1&2 and 3&4 on newer models. We were thinking about it as well.
Gearbox will be undercut, crankcases will be vented, fun will be had.

[katana]

I know APE make 'em for the GSX/EFE and my ancient APE catalogue does list them for the GSXR!

[gixxerharry]

And those are stronger studs? or do you only think there stronger?
(removing the studs can be a big problem)

[katana]

Oct 24, 2014 17:23:18 GMT gixxerharry said:

And those are stronger studs? or do you only think there stronger?
(removing the studs can be a big problem)

Stronger ? Don't know - but they are harder / hi tensile / low stretch so should provide a consistant clamp of the cases if tearing them down regularly , racing for example. The std. studs are very springy so suited for their use as fit, torque and forget in the factory!

[gixxerharry]

Okay the tearing down thing is a good reason and class A thread is also nice (dont fuck it up by retreading it whit a Tap)
If have red several times on several fora that the stock suds are strong enough or even stronger i have never seen or red that they fail and they are a bitch to remove (seen that fail a lot)

And even if there not stronger i think for a turbo bike it is good idea to use the head gasket as a fail save
If the bike blows a head gasket there is a problem (pinging)
And gaskets are a lot cheaper than pistons

Just a thought