1984 GSX 750 EF down under

[Loccoli]

Here are some progress pics from the last week or two:

Brakes getting taken apart, painted and rebuilt with new seals, pistons, stainless lines, etc.





Not the best job but looks much nicer on the bike.

As for the r/r, it seems if I turn the cdi upside down it creates just enough space for the SH775 in the stock r/r location. The holes in the brackets are a mm or two shy so I'll try some incantations to stretch it out.
I need to be careful of edges of wires with the harness running to the top of the bracket instead of the bottom but should be able to package it safely. Only other concern are the cables from the shock rubbing on the r/r.
This is it mocked up:


I can put some foam tape on the corners and/or a sleeve of some kind on the cables.
I may end up buying a YSS rear shock down the track so those cables wouldn't be an issue then.

Hopefully I can get the r/r wired in today.

[Loccoli]

Like a lot of people, I've had a bit of extra time the last couple of weeks, so I finished off the GSX (for now). There is still a bit of cosmetic work to do, but it runs like a dream and everything seems to work. The worst part of all this is that I have this lovely bike sitting here raring to go and I can't in good conscience take it out for a spin. I've only been able to ride it around the block a few times to make sure everything worked. I will definitely be taking it to the shops when I only need a couple of things, as that will count as an essential trip!

Here it is:

]





The rec/reg went in without a hitch. As previously mentioned, mounting the CDI upside down made enough space for the SH775 to fit in the stock position. Some gentle persuasion (hammering the ridges of the bracket) made the original bracket line up nicely with the holes in the new r/r.

I rebuilt the brakes and added braided steel lines - unfortunately the rear line was 10-20mm too short. It would reach if it were "floating" but not routed through the loops on the swing arm, so I've put the rubber line back on the rear until I can get HEL to send a replacement. The rubber ones are in fine condition. They were probably replaced by the PO.

New Pirelli Sport Demons to replace the brand-new looking 11-year-old Sport Demons that were on it.

Down the track I will probably rebuild the forks and use the opportunity to paint the fork lowers. This will wait until I can afford new springs and rear shock, and possibly cartridge emulators.

Otherwise there are some cosmetic things to do like clean and polish the wheels, but at this stage I just want to ride it! It's such a bittersweet feeling to have finished the work I wanted to do on the bike but not being able to go for a good ride!

Thanks to all of you who have shared knowledge on this site, I have spent many hours poring over threads getting my head around things I didn't understand or know how to do, and it's paid off. This is my first project and first straight roadbike and it's safe to say I wouldn't have been able to do it all without this site! I know it's not a big project by the standards set on here, but it was for me! Special thanks to Nessism for supplying me with a tested r/r. I hope it will prevent me having to deal with electrics too often!!

It sounds really nice by the way. A bit loud but not Harley narcissist (Harlissist?) level loud. Let me see if I can post a video...

Stay safe out there folks!

[Loccoli]

Click the picture for a video

[GregT]

Welcome to the site.
That jetting is stock. Don't know what manual you've looked at but it's "rest of world" jetting. Aus, UK, NZ got that jetting.
Suzuki often varied jetting between markets according to what emission standards they had to achieve.

It was very apparent a couple of years later. The early GSXR750 export versions with slide carbs had totally different jetting to the Japanese home market bikes. And the US market got CV carbs....

[Loccoli]

Thanks Greg.

Yeah I worked that out once I got hold of a service manual! I also discovered that our wheel and tyre sizes are different to the rest of the world. 120 front instead of 100 and 130 rear instead of 120. I was home sick one day a while ago and thought I might order tyres. Glad I went out to the shed to double check before I did and didn't trust online specs. Lesson learnt!

[steve murdoch]

Bike turned out great, Loccoli.
Like the sound of that pipe too, i am going to guess Marving?

[GSXR7ED]

Late to the party...and I understand the delay in updates...it took a year for me to start posting some pics of our trip to Ireland in Mar/2019.

That is a sweet looking bike you got there. I did a master cylinder/caliper/braided line upgrade rebuild for my bike. Yours looks much more gunky than mine was...but it cleaned up nicely as I'm sure yours did too.

Keep up the good work!

Ed

****

[Loccoli]

Bike turned out great, Loccoli.
Like the sound of that pipe too, i am going to guess Marving?

Right you are! Marving "race" model with the baffle in. Fitment required a bit of wrestling - it was almost like it was made to fit two types of bike and the spacing of the headers is between both. The muffler doesn't sit the way you'd expect either. You would think the text would face outwards and the screw hole midway down the muffler would face downwards, but the text needs to face upwards and the hole to the side for it to clear the centre stand. Once on it's good though. Looks and sounds great, the flat collector is great for ground clearance and it's nice to be able to keep the centre stand. I had to trim a slight curve into the lower fairing so it didn't rest on the exhaust, but I think it did that with the stock pipes as there was already a little melted section where I trimmed it.

I tried to match the curves of the fairing and exhaust so it doesn't look like too much of a hack job. To be honest you'd need to put your head down there to see it anyway:

[Loccoli]

Late to the party...and I understand the delay in updates...it took a year for me to start posting some pics of our trip to Ireland in Mar/2019.

That is a sweet looking bike you got there. I did a master cylinder/caliper/braided line upgrade rebuild for my bike. Yours looks much more gunky than mine was...but it cleaned up nicely as I'm sure yours did too.

Keep up the good work!

Ed

****

Thanks Ed. You think the front master cylinder looks bad, you should have seen the rear! The piston was so gummed up I couldn't move it it in the slightest, not even with compressed air. It looked like the piston was part of the cylinder. I ended up drilling out the centre of the piston very carefully so I could get something in there to loosen it up and force it out. I was probably lucky not to damage the bore.

[Guest]

Fantastic result! She looks good and that pipe... yeah that sounds great

Not being able to ride as you want right now is really tough, especially just after finishing! I'm struggling with it as well but at least I've had 10 months of riding with the Kat since I finished it.

I hope you get some essential things to do so you can get some essential rides in and enjoy it!

[Loccoli]

Thanks Pete. I live in a rural area so I can justify a ride on some country roads to find flour or sugar which are often out of stock at our supermarket. The weather is holding me back right now - 5-10 degrees and constant rain. The other worry is I haven't broken in the new tyres, and I don't know if I can ride far enough to heat them up long enough to do so.

Oh well. Once this is all over I think I will appreciate the privilege of riding even more and take every opportunity I can get!

I think my next project will be to strip back my XR600 and build it up for adventuring.

[Guest]

Ah lucky man! Everything for me is 2 minutes ride away... I must admit when asked to pick something up I don't go directly there and back, although I'm obviously not doing big detours via the hills!