1979 GS750E Rebuild

[GSXR7ED]

Jo's Rebuild

Thanks. She is kinda cute. She was in my sig line for a while and I did start a thread last year when I first got her. Unfortunately then the health issues started that ended with my heart missing on two chambers and needing a bump start to get it going again. However, I'm now back running again. Just done 2 mile with an 11lb rucksack on my back in 18 mins. A little slow for me and I need to get the endurance back up to to the 6 or 7 mile mark but still, considering I had a heart attack 4 months ago and I'm in my mid forties, it ain't fecking bad if I do say so myself

Well, you're in better shape than me; that's for sure! Glad you overcame this condition and your bike can get your full attention.

Rough plan is to give the EC a full strip, service and spit and polish rebuild. Besides those shields all I really need now is a new set of tires, new battery, couple of shims (already checked), new oil and air filters, complete gasket and seal set.

Sounds like nothing too major. I've got some tasks to do on my bike too.

I've found a guy who specializes in renovating old 70's carbs so I'll probably send them to him to get the full treatment. Just be easier, quicker and he has all the gizmo's, bells, whistles and experience to get a better finish than I ever could.

Yeah, sounds like something I'd do...have it done by someone who's rebuilt them so often they can do it with their eyes closed.

The bike already has a period electronic ignition system fitted that is working perfectly. She was running, although lumpy, before. Way to lean on the pods, with partially blocked and broken jets etc etc. However I've not checked the alternator output yet. As far as other modifications go, I'm really aiming to keep this as true to original as possible. With a genuine 30,000 miles on the clock and a 99.9% stock 36 year old bike, I just think it would be criminal to start modding her.

Keeping her just the way she is sounds great! I'd switch back to original air filter--which will take some work if you don't have the original parts.

Saying that, a new set of rear shocks and some inserts for the forks are on the wish list. Oh and a new paint job. That green really clashes with my red leathers

Jo

I put new Progressive Shocks and a Fork Stabilizer, and fork oil (thanks to Bill) on mine and she feels Great! The tank needs to be repainted...I actually like the solid black on mine. Enjoy your work on her and fill us with pictures of your activities.

Trust me. I'm already pushing my luck with blond hair, blue eyes and red leathers. Throw in green and I'm gonna look like a gangrenous elf! Not a good look for cruising the beach front at St. Tropez.

I'm sure you could get away with the color clash.


Ed

[JAG]

The fairies brought my pressies from the Goddess.

Look filthy but all there. Bike was a GS750B barn find that had been standing for 25 years. Sorry about the size of the pictures.



Seals in perfect condition.



Both sides. Even has the snorkel type bit



And with the carbs.



So there I have a filthy but complete set of carbs/airbox assembly for $176 delivered to my door.

What I have to figure out now is how to remove the seals without damaging them. Any advice?

[GSXR7ED]

Removing Seals/Boots

^^Nice!

This is where you'll find out the condition of the rubber seals...if they're pliable.

When I removed the carbs off my "T", I pivoted/rotated the carbs back and forth until they shimmy off the inlets. Oh, I removed the clamps completely on all 4 seals; so I didn't scratch/damage the seals.

Take pics and good luck.


Ed

[eil]

The seals should just gently pull right off the box. Not sure if they're held in by anything from the factory, but my 850 (with the same airbox), they come off with no effort. My bike is down for winter maintainance and I plan to reattach my seals with a bit of silicone on the lip underneath so they make a good seal and keep moisture out. Then weatherstripping on the inside of the chrome covers to make sure they seal against the rubber seals.

[Brendan W]

What I have to figure out now is how to remove the seals without damaging them. Any advice?

Warm water won't do any harm.

[JAG]

Well I'd love to get stuck into the airbox but I'm out Doo Wopping and Burlesque, so the work will have to wait till the morrow.

Plan on the airbox. The side seals are crucial to be kept intact as is the snorkel bit as you can't buy them. As I'm sure many of you know. However if I can get them off intact, not only can I use them again, but I should be able to use them as patterns to have spares made up.



There's a lot of gunk so I really want to get inside the box to give it a real good clean.

As for the trumpet inlets, I already have a brand new set waiting to go on.

The plan at present is preheat my oven to 70C, (after all I don't cook in it) and after removing all ancillaries heat the box and rubbers up to temp to see if they soften and come away nice. (fingers crossed)

If they do great, just a case of washing the box (now now behave), before giving it a good rub down and respray.

Side covers are actually in ok condition. No dents just flaking chrome and surface rust. I'll clean them back down to bare metal and send them for a rechrome with some other bits later. Or maybe I'll just respray them black. Who knows.....

In short the final bike is being pulled in several directions. Sort of in a mind to just get her running and on the road for minimal fuss, and then focus on the "B".

[Brendan W]

Don't know what kind of oven but I wouldn't. Parts of it can be a lot hotter than 70C not to mention metal bits absorbing radiant........blah blah.
Basin of water wont do that and you'll get some cleaning for free.

[JAG]

Don't know what kind of oven but I wouldn't. Parts of it can be a lot hotter than 70C not to mention metal bits absorbing radiant........blah blah.
Basin of water wont do that and you'll get some cleaning for free.

Old electric oven. How about I turn it regular like a roast?

Hmmm..... OK maybe I'll try the hot water first.

[Brendan W]

Old electric oven. How about I turn it regular like a roast?

Hmmm..... OK maybe I'll try the hot water first.

Good move. Its probably got a bang bang controller and the elements will be over 500 at times and the heat capacity of your pressie ...........................

[JAG]

Good move. Its probably got a bang bang controller and the elements will be over 500 at times and the heat capacity of your pressie ...........................

Bang bang controller? My pressies heat capacity!!! Why Mr Brendan.... Maintain some decorum sir. I beseech thee

[JAG]

So the airbox has been stripped to component parts.

Removal of the seals was easier than anticipated. All I did was gently lift the inner edges to free them up where possible, and then ran a blunt edge around the rim gently prying and lifting as I went.

As can be seen in the following set of photos the box is in excellent condition for it's age, with little to no corrosion in the common areas such as the engine breather inlet.

The foam filtre element seal will need replacing.

As will the filter element. Although this was always going to be the case, I found it interesting what 36 years of oil does to a piece of foam...

This just crumbled to the touch....

....leaving nothing but coffee grains.

I have new carb boots already, so besides a new foam seal for the filter and a new filter element, all that needs to be done is a good wash and possibly a respray

'appy daze.

[eil]

Yep, mine did the same thing. Horrid stuff. I replaced it with a K&N filter that I got on eBay. Supposed to be good for a million miles, if you clean it semi-regularly and believe their marketing.

[JAG]

Yep, mine did the same thing. Horrid stuff. I replaced it with a K&N filter that I got on eBay. Supposed to be good for a million miles, if you clean it semi-regularly and believe their marketing.

Yeah that's the plan here to. The K&N is on order at the moment. Meawhile I found another set of end covers for the box that I'd forgotten I had. They've only a couple of dings so they're back on. Also decided a respray can wait till later. As a result the box is on and in place. Just waiting on the carbs to come back from their clean and rejuvenation service.

After that I'm just gonna replace a leaking head gasket, sort the valve timing, give the head, cam chain tensioner a little clean, new oil filter, new battery, new tyres and get her back on the road for the end of February / beginning of March.

The full rebulid will occur later in the year. Pictures will follow of the airbox in place soon.

[GSXR7ED]

That's a busy looking airbox. I was able to acquire a secondary airbox for my Parts Bike from a fellow GSer. She's on my to do list so that's why I am interested in how much of a breakdown/rebuild you will be doing. Here she is all alone in the garden shed:



I have an engine stand from Harbor Freight (HF) which cost me <$40 and I'm very excited to see the intricate details of the motor. Not sure when I'll be doing this task as I am working as a contractor 800 miles from home.

I still haven't decided if I want to bring my Riding "T" to Florida...she needs lots of work and storage is the main concern...not only for her but my foldable trailer which I also bought from HF.

The airbox I purchased did not have all the inner parts you have on your recently purchased airbox. All I used was warm water and dish soap to wash but I never took pics.

Continue updating...I enjoy your replies.


Ed

NOTE: Here's some random pics I found with my riding "T" airbox...along with other components.

[JAG]

That's a busy looking airbox. I was able to acquire a secondary airbox for my Parts Bike from a fellow GSer. She's on my to do list so that's why I am interested in how much of a breakdown/rebuild you will be doing. Here she is all alone in the garden shed:



I have an engine stand from Harbor Freight (HF) which cost me <$40 and I'm very excited to see the intricate details of the motor. Not sure when I'll be doing this task as I am working as a contractor 800 miles from home.

I still haven't decided if I want to bring my Riding "T" to Florida...she needs lots of work and storage is the main concern...not only for her but my foldable trailer which I also bought from HF.

The airbox I purchased did not have all the inner parts you have on your recently purchased airbox. All I used was warm water and dish soap to wash but I never took pics.

Continue updating...I enjoy your replies.


Ed

Nice looking bike. I don't know much about your airbox as it looks different to mine. However if your missing the inner rubber end seals as I expect, and possibly the foam seal for the air filter unit, I was looking at how I could make these up to repair my other box.

Basically I made some blanks using a packing foam and planned to hand cut some rubber sheeting. I did a search for the necessary oil/heat resistent material for seals on interwebby thing and found you can get the stuff on eBay for about $30.

I post up some pics and links later. Hope this helps.