1977 GS750 Cafe/Brat Build

[rlink182]

Finally think I have a project that I can finish. I have tried building other vehicles in the past, my issue was that I had too many idea's and not enough money/time/*insert excuse here*.

So what do I have here? I have a 1977 Suzuki GS750. I traded a supermoto for it, when I got it, the previous owner had "restored" it to the first picture I am posting and he did a pretty good job. It was not bad, it was running and I could daily drive it without any real concerns. But I wanted it to run better so I had a plan, why do those always seem to go out the window so quickly..... Well my plan was to do a basic carb rebuild, clip-ons, headlight bracket and check the valve clearance. Pretty simple plan, but I didn't plan ahead enough and I ended up ripping the valve cover gasket, and I didn't have the right feeler gauges or the tool to pull the valve shims.

So I figured if I need to buy $50 worth of stuff, I may as well redo the entire bike.

Start the shopping spree, believe me, this was not my original intent. Bike was supposed to be down for only a weekend while I rebuilt the carbs.

Here is a quick list of the things I hope to see sitting on my porch soon, or I already have in hand:

Clip-ons
Headlight Bracket
Vintage BSA Headlight bucket
Dime City Throttle Tube
Rear Hoop with upsweep
Rear Tail light
Switches
Tach
Speedo
Carb Jets
Pod Filters
Mufflers
Biltwell Grips
Valve Shim Removal Tool
Valve Cover Gasket **Only real reason I started the project**

I am also in the process of rewiring the bike, I am going to go kick start only to eliminate any issues. The bike started up great even with horrible carb leaks and rubber that was more goo than elastic.


So how far am I?

Bike is in pieces
Carbs are rebuilt but will need new jets when they arrive
Cleaning is at 50%
Clip-ons are mocked up
Headlight brackets are in place
Wiring has been removed
Wiring diagram has been created
Trying to get the damn stator cover off
Looking for seat material and hopefully buying metal for the seat pan today.



I will be posting the good pictures on instagram, if you are interested you can follow me here:
https://www.instagram.com/rlink182/

More to come,

Ryan L.

 

[rlink182]

Driver View

 

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Bikes Personal Escort

 

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Carbs Pulled off the bike

 

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Parts just falling off of the bike

 

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Only about 75% disassembled.

 

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Headlight bucket showed up yesterday

 

[rlink182]

Favorite Picture so far.... Lack of Organization can kill a project. What you don't see is me cleaning up everything picking tools off the ground before I snap pictures. lol

 

[Guest]

I'm looking forward to this one! That looks to have been in really good shape they way you got it. I certainly know how projects can balloon rather quickly. My cafe/brat whatever was basically done, but I decided to change the battery location and rewire it for a 2nd time. I'm probably going to miss half of the riding season.

Best of luck with the build!

 

[Guest]

Finally think I have a project that I can finish. I have tried building other vehicles in the past, my issue was that I had too many idea's and not enough money/time/*insert excuse here*.

It usually is a case of not enough focus along with a bit of time management. People let perfection override good enough and then get caught up in project creep until they drown and then sell the mess off to the next guy.

Dime City Throttle Tube

Can I ask why?

I will be posting the good pictures on instagram, if you are interested you can follow me here:
https://www.instagram.com/rlink182/

I would but I avoid the social media like the plague. It looks like you had a nice starting point to jump off from, hop it turns out the way you are hoping.


Mark

 

[rlink182]

@JonnyC - Thanks! Really not looking forward to the bike being down, but I am going as fast as the parts arrive. I don't want to miss riding in a San Diego Summer!

@mmattockx - I definitely have the focus this time. I think the previous projects were to much to take a bite out of (cars vs bikes). I have always completed my bike projects. I had a pretty wicked Yamaha Raptor that was down to the frame. I wanted a new throttle tube to clean everything up, I am getting rid of as much as legally possible.

During lunch today I picked up the metal for my seat pan/underseat storage, I also picked up some metal for my new gauge mount in stainless. I put in an order for high density seat foam and picked out my fabrics. Now I need to find someone that can sew it all together for me, wife won't let me touch her sewing machine. I want pleats and if you have seen her try straight lines, you would understand why I am looking elsewhere to outsource it.

 

[rlink182]

Mufflers Arrived!

 

[rlink182]

Got the Metal to build my seat pan. I also found a guy to build my seat for me. the little metal sheet at the bottom is stainless to make my gauge mount.

 

[rlink182]

Finally got that damn stator cover off, that was tricky. I had to go and buy new bolts and gasket for that one. I have since removed the starter.

 

[rlink182]

Wiring diagram is close, still have some little things to sort here and there.

 

[rlink182]

Parts pile is growing, most of this stuff won't go back on the bike.

 

[rlink182]

I thought this picture looked pretty neat

 

[rlink182]

So I rest fitted my headlight into my bucket, light is bigger by over about an inch. Need to decide if I want to keep my current bucket/light, or find a new light to fit my new smaller bucket

 

[Guest]

View attachment 46080
Mufflers Arrived!

Can you take a shot looking down the core of these? I am curious how they are built inside and how big the passage(s) and outlet are.


Mark

 

[rlink182]

Can you take a shot looking down the core of these? I am curious how they are built inside and how big the passage(s) and outlet are.


Mark

When I get home I will, I took a quick look and I believe it had a single sheet of metal as the blocking with 1/8" holes drilled through it. I will get measurements for you also, they came with various sized spacers.

Ryan