78 GS750 engine overhaul on the Cheap!

[rphillips]

Looks like about all back to exactly like it was back then, Loving it all., Wondering if a GS1100E alum. swingarm would bolt right in there as easy as the steel one? Liter, never rust, a bit stronger, and still an OEM Suzuki part... Like I said, loving it all.

[Bobbys 94]

Notice that the rear tire still has lil nibblets on it, not many miles where put on the two tires but they are 38 years old. If you look close at the sidewalls you can see tiny cracks throughout the entire tire.
Installing new Dunlop tires with new tubes and rim strips as we speak.

[Bobbys 94]

Pic below shows the "3" different brands of bearings and to my knowledge, NSK was the bearing manufacturer of choice by most metric bike manufacturers, back in the day. Only one of my removed bearings is NSK, the front set is Turkish made and two of the rears are unknown manufacturer. The front brgs could not be turned by hand after the wheel was removed. One of the rear hub brgs was the same. The only NSK brg was the sprocket/carrier large brg. It's grease was also like candle wax.

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[Bobbys 94]

Other side of my GS. Removed swingarm and it needed it, About 38 years ago! Swingarm needle brgs had only hard grease in them. Kinda like candle wax. No" Lubrification"
I rebuilt both brake master cylinders and both calipers. New brake pads and new front brake hoses. Dot 5 synthetic fluid.

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[Bobbys 94]

Pictured below is what I've begun to service on my GS.
Forks had little to no fluid in them and seals were dry and brittle. Front wheel bearings made some noticeable noise while riding. Rear hub/carrier felt warmer than it should have for only going 6 miles. So I did what everyone should do on a 47 +- year old machine that you plan on counting on for a safe and reliable ride "Every time"
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[Bobbys 94]

Got the GS running like new. Everything works as it should. Rode about 6 miles going through the gears and all felt pretty good for a 47-year-old machine. I plan on keeping this at least until my grandson shows interest and is worthy owning and riding this machine and the upkeep that goes with it.
The pic below shows how it looked after most of the general maintenance had been done and a good cleaning/polishing.
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[Bobbys 94]

Left side close up of the engine.
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[Bobbys 94]

A couple token shots of the engine. It cleaned up very nicely.
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[Bobbys 94]

Left side of the GS750 just because
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[Bobbys 94]

This is on my lift and ready to start the resto. I will be keeping this 1977 GS750 in stock configuration. After soaking the entire bike in about a gallon of WD40 over the past month this is what I have to work with now. I did have to buy all the engine side covers because they where all missing including the stator assembly. I did do a little hand polishing to them before I installed them. Now the tear down begins.
My goal is to replace anything that is wore out or in need of replacing due to old age. Complete carb rebuild, fork seals, all wheel bearings and seals, tires and tubes, triple tree bearings, all brake components

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[Bobbys 94]

The "Cheap" GS750 engine build just became "Not Cheap" GS750 engine build. Thanks to a member I now have a Weisco 850 kit for the 750. Along with many other rebuild pieces like:
APE valve springs
8 new valves
Complete OEM gasket set
Schuman valve guides
OEM Intake boots
20 new head bolts
Barnett fiber and steel clutch plates with clutch springs

You have to want to do this for "YOU/ME" because you'll never get what it's worth if you try to sell it. My intentions have never been to build this for resale to anyone. It keeps me busy and I learn something every day working on these projects.
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I won't be starting the 850 kit until I'm done with my 1977 GS750 project shown below.

[rphillips]

That's interesting, I never heard only 1 half of eng. case was painted. Hope somebody may have more info.

[Bobbys 94]

Not sure what the process was called "Back in the Day" but there was a process. The process of coating the surface of the cylinder, cases, cylinder head and valve cover to protect against corrosion. It can be removed with chemicals but it will still boil down to "Elbow Grease" at one point.

[MaurieG]

Marcus,
I did remove the head and cylinder while the engine was still in the frame. My engine was not painted black it just had the factory silver which came off pretty easy with stripper and elbow grease. I think that in your case I would either remove the engine and get it vapor blasted or tear it down completely and work on the individual pieces one at a time. Either way, it's going to be a lot of work. It looks like you're committed now so keep up the good work.

You mention 'Factory Paint' on the engine. I'm in the process of restoring my '78 750EC. I was led to believe the only part of the engine that came painted from the factory, was a crankcase half. Up to now, I've never found out which half that was! Can you, or anyone else following your build, enlighten me, please?

[Bobbys 94]

The tank is beautiful and all original. Came with a factory Suzuki key that matches the ignition, gas tank lock and seat lock.

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