1989 GSXR 1100 ground up rebuild : Suzuki GSX-R Motorcycle Forums: Gixxer.com

**89Basketcase** · 12-18-2012, 02:25 PM

I have a 1989 GSXR 1100 that i bought for 250$. The drawback was that it was in pieces....several pieces. I bought this bike because i love it and i wanted a decent project. i have all the parts (Plastics, rolling chassis, motor etc...). I cleaned all the plastics and removed everything from the rolling chassis so i could take inventory of what i need to replace. I am waiting on breaking down the frame until i can get the motor finished. I have followed both the Suzuki Service Manual and the Haynes Repair Manual.

I have been taking my time in disassembling and labeling and bagging practically everything on the motor. I haven't run into any major problems ie..no broken/stripped bolts, no cracks <knock on wood>.

I am stuck at splitting the crankcase though. I can hear that parts of the split have separated when i tap it with a rubber mallet, but some part of it is still binding. I think it is in the recessed corner around the transmission output shaft.

Any thoughts on if i am missing anything, or tips on how to split a case thats nearly 25 years old?

Pictures available if necessary.

**gixerhp** · 12-18-2012, 04:54 PM

Do you have the case bolt that is inside the generator hole?

**89Basketcase** · 12-18-2012, 05:29 PM

Quote:

Originally Posted by gixerhp

Do you have the case bolt that is inside the generator hole?

If you are asking about the signal generator, then there was one bolt holding the rotor and then 3 bolts holding the stator, and all of those have been removed.

**FruitLooPs** · 12-18-2012, 05:42 PM

He means the alternator, from another thread:

" There is another well hidden bolt from the top. On the alternator mount housing there is a plug, under that plug is the hidden bolt. "

There is a few ninja bolts, but if you take your time you can find 'em all.

**wicked86gsxr** · 12-18-2012, 05:42 PM

Welcome to GDC, get your red r than you can buy/sell in the classifieds and much, much more.

**FruitLooPs** · 12-18-2012, 05:45 PM

image of an 88 750 motor showing some bolts from a previous thread, also mentions under oil filter etc. 1100 should be very similar.

**89Basketcase** · 12-19-2012, 11:14 AM

Found all those ninja

bolts previously. i did find one that i missed though. It was attached to the oil return tube in the oil pan. I don't remember the manual stating anything about removing that one.

I split the case and bagged the trans, trans cam, forks, and oil pump. the only thing left in the case is a couple of the dowels and the two bearings from the transmission.

Everything is in great condition, no chips, no shavings, even the bearings roll without any grit.

**CHEMOTO** · 12-19-2012, 12:46 PM

sensational m8. im following you now.

check out the transmission shaft bearings btw. I completely overhauled the engine due to a second gear that popped out and one of those bearings was with its intestines out. no need to say that new ones will be installed...

cheers¡¡