Have made the decision to rebuild the 1500 engine and to do this hopefully before next summer, but more realistically fall of 2021. C-19 could help with moving this project up to this fall/winter.
Not a lot of information on the various forums regarding 1500 engine rebuilds. Found one YouTube video, and lots of threads on the ancillary items, and why would you want to.
Have considered a used engine, but the availability in Canada is quite a bit less than in the US. Importing an engine from the US is cost prohibitive. I mentioned on my other thread viewtopic.php?f=7&t=14098 that selling and buying a depreciating asset such as a motorcycle is an exercise in spending money. Better to invest a smaller amount into a known entity than to start new that comes with work/maintenance that you have already taken care of with the bike you presently have.
I notice what seems to be a gearing noise when the engine is at idle. This could be a bearing issue. Have perused the various forum threads and have found information that indicates gearing noises in the 1500 engine are a result of worn bearing(s).
Have been gathering information regarding costs. Parts availability is better for the 1500 than the 1200. Unfortunately have to rely on ordering from the US and Europe. Estimate the cost of the engine rebuild will be $2000.00 to $2500.00 CDN with the labour being done by me. If I'm going to spend money on this bike after having done the paint job, want to do it sooner than later so I get to enjoy it - don't want to do work later for someone else to enjoy. Should have at least another good 10 years of trouble free riding, and as this is not a long time it will go quickly, no reason the bike won't make it - jury is out on the owner.
The only external work will be the machine shop if needed. Won't be able to determine this until the engine is taken apart and the exhaust valve seats are inspected, and what shape the cylinders are in. I'm hopeful that the engine will be in a similar condition to that of my 1200, cylinders were good and only a hone was required.
The rebuild will have new crank journal and con rod bearings, set of piston rings, valves lapped or have machine shop do work. If I use the machine shop will have heads and cylinders done there with a requirement to make sure the heads and block are true and flat.
New clutch to be installed, engine is apart, don't want to revisit. I towed a trailer last year, and it's realistic to think a PO did as well because the bike came with a trailer hitch. My 1200 had a hitch installed and I was told that a trailer was pulled. I pulled the engine for stator work and at the same time inspected the clutch. All steel plates were blue in colour indicating an overheated condition - 115,000 Kms on the clock at the time.
New water pump may be installed, along with other items.
Carbs will be rebuilt as well. 25 years and 176,000 Kms can take a toll on any mechanical part.
Good time to renew all vacuum hoses, and possibly install SS brake and clutch lines.
Will be looking at the various OEM connectors, inspect, take apart, clean and put back together. The 1000/1100 fraternity restore/refurbish on a regular basis, why not the 1500 crowd.
There are special tools required for this build, specifically when putting the case back together. There are two jigs needed to support the pistons and piston ring compressors. May be able to use hose clamps for the 1200, but I think the 1500 will not be as forgiving. The ring compressor(s) are the expensive part. The parts needed are:
Piston Ring Compressor(s) – qty 3 – P/N 07JMG-MN5000A
Piston Base A – qty 1 – 07JMG-MN5012A
Piston Base B – qty 1 – 07JMG-50111
Crankcase support blocks – wood – 1 ½ X 1 ½ X 3 3/8 inch (40 X 40 X 86 mm)
Will be checking the hydraulic valve clearance. The shim tool for the 1200 is used on the 1500 as well.
Have been perusing the OEM service manual, mine is for a '99, but should be the same. The level of complexity is more than the 1200, but manuals can make the simplest task appear to be more daunting than the task is.
My readings indicate that the crankcase assembly will be the most demanding part of the rebuild. Need special tools, and a second set of hands is recommended. Applying the crankcase sealant will be a challenge as there are two hard to reach surfaces that need to be coated.
More to follow.
Not a lot of information on the various forums regarding 1500 engine rebuilds. Found one YouTube video, and lots of threads on the ancillary items, and why would you want to.
Have considered a used engine, but the availability in Canada is quite a bit less than in the US. Importing an engine from the US is cost prohibitive. I mentioned on my other thread viewtopic.php?f=7&t=14098 that selling and buying a depreciating asset such as a motorcycle is an exercise in spending money. Better to invest a smaller amount into a known entity than to start new that comes with work/maintenance that you have already taken care of with the bike you presently have.
I notice what seems to be a gearing noise when the engine is at idle. This could be a bearing issue. Have perused the various forum threads and have found information that indicates gearing noises in the 1500 engine are a result of worn bearing(s).
Have been gathering information regarding costs. Parts availability is better for the 1500 than the 1200. Unfortunately have to rely on ordering from the US and Europe. Estimate the cost of the engine rebuild will be $2000.00 to $2500.00 CDN with the labour being done by me. If I'm going to spend money on this bike after having done the paint job, want to do it sooner than later so I get to enjoy it - don't want to do work later for someone else to enjoy. Should have at least another good 10 years of trouble free riding, and as this is not a long time it will go quickly, no reason the bike won't make it - jury is out on the owner.
The only external work will be the machine shop if needed. Won't be able to determine this until the engine is taken apart and the exhaust valve seats are inspected, and what shape the cylinders are in. I'm hopeful that the engine will be in a similar condition to that of my 1200, cylinders were good and only a hone was required.
The rebuild will have new crank journal and con rod bearings, set of piston rings, valves lapped or have machine shop do work. If I use the machine shop will have heads and cylinders done there with a requirement to make sure the heads and block are true and flat.
New clutch to be installed, engine is apart, don't want to revisit. I towed a trailer last year, and it's realistic to think a PO did as well because the bike came with a trailer hitch. My 1200 had a hitch installed and I was told that a trailer was pulled. I pulled the engine for stator work and at the same time inspected the clutch. All steel plates were blue in colour indicating an overheated condition - 115,000 Kms on the clock at the time.
New water pump may be installed, along with other items.
Carbs will be rebuilt as well. 25 years and 176,000 Kms can take a toll on any mechanical part.
Good time to renew all vacuum hoses, and possibly install SS brake and clutch lines.
Will be looking at the various OEM connectors, inspect, take apart, clean and put back together. The 1000/1100 fraternity restore/refurbish on a regular basis, why not the 1500 crowd.
There are special tools required for this build, specifically when putting the case back together. There are two jigs needed to support the pistons and piston ring compressors. May be able to use hose clamps for the 1200, but I think the 1500 will not be as forgiving. The ring compressor(s) are the expensive part. The parts needed are:
Piston Ring Compressor(s) – qty 3 – P/N 07JMG-MN5000A
Piston Base A – qty 1 – 07JMG-MN5012A
Piston Base B – qty 1 – 07JMG-50111
Crankcase support blocks – wood – 1 ½ X 1 ½ X 3 3/8 inch (40 X 40 X 86 mm)
Will be checking the hydraulic valve clearance. The shim tool for the 1200 is used on the 1500 as well.
Have been perusing the OEM service manual, mine is for a '99, but should be the same. The level of complexity is more than the 1200, but manuals can make the simplest task appear to be more daunting than the task is.
My readings indicate that the crankcase assembly will be the most demanding part of the rebuild. Need special tools, and a second set of hands is recommended. Applying the crankcase sealant will be a challenge as there are two hard to reach surfaces that need to be coated.
More to follow.