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77 GS 750-Cafe/Fighter

  • Thread starter Thread starter z33kyle
  • Start date Start date
That thing is starting to take shape....keep it up man, when you finally take that thing to the local bike hangout it will all be worth it!

I've always like the lines of the stock E-model tank...I just took some reinforced bondo and molded in the crappy seam. Makes 'em look a lot better...I painted mine with a rattle can too, maybe have $1500 in the whole thing over the years.

I am doing an 1100 swap soon, so that is about to change, but I am emotionally attached. Bringing an old bike back from the grave is a rewarding experience, if you have the time, patience, and some cash.

I was going to make my own tail section, like yours, but I got lazy and used an XR-750 clone I was saving for my RD400 project. Didn't look right on that one, but I thought it looked great on the GS.

I did see a how-to where a guy made a tail section using the blue foam insulation you get at Home-depot, cut, glued and stacked in the rough shape, then fine tuned with various grades of sandpaper. He finished it off with bondo and used it as a plug for a mold.
Also have seen the same basic foam technique, but covered with fiberglass to form a shell, then the foam removed.

Good luck with your project!
 
Thanks man, yeah I was going to use what I have so far as a plug for a mold but it is taking so long I might just remove the foam and finish it off.

I just rebuilt the carbs yesterday and boy do I have a new respect for carburetion.
 
Love it, keep going.

I have struggled with a seat design from day one and still do not have it nailed.
Like what your thinking with the seat.
 
Nice.

Nice.

Sorry to hear about your starter woes. Glad you worked something out with the manufacturer. Nice looking seat man. How much glass do you have there?

Scott
 
I love z33's :D

Anyways, that rear end is looking good. Great job with the bike.
 
Thanks for the comments everyone. I am getting closer to having the tail ready for filler and paint. I just haven't had any time to mess with the bike. I bought another project car so my time has been invested in it, and also I found out how much title recovery was going to be and it has me discouraged. I bought the bike thinking that recovery would only be like a hundred dollars, but now I am finding out its going to be more like three hundred dollars plus. I'm hoping I can devote some time this weekend to the bike though.

I have quite a bit of fiberglass in the tail. My dad was given an industrial role of fiberglass cloth and he passed it off to me. So far I have three layers of cloth on all the surfaces with a backing sheet of thin sheet metal underneath where your butt will be. Its about 3/8" thick all the way around. My biggest thing to do right now is figuring out mounting brackets. I'm thinking of making a metal frame and glassing it under the rear portion of the tail and then using quick release fasteners to secure it to the frame. I have the frame bobbed right now with a piece of flat stock welded between the two frame rails. I'm still undecided though.
 
http://www.facebook.com/home.php?#!/video/video.php?v=10150115002744772&subj=636449771

This is a link to what I accomplished over Christmas break. She won't fire up without using starter fluid but once she fires the engine stays running. After running the engine all the little leaks are starting to show. The valve cover gasket is leaking close to the forward cam, so I am going to replace it and I ordered a starter delete plug off of Z1 since I don't believe I am going to be able to use my starter.

I plan on embedding the video once I am not on my work computer.
 
Kyle it will run much better with an air box/filter on it. They don't run that well without the airbox. Sounds good though.
 
Yeah, I was just trying to see if it would actually run. This is probably the first time its ran in ten years or more. I have pod filters on order and I am currently trying to source a used 4-1 exhaust. Once I find an exhaust I will get the proper jets and what not. I have a friend that works for Rotary Recycle, which is a rotary motorcycle shop in Tennessee, who will help me sync the carbs and get everything tuned.
 
So I have received my pod filters and a starter block off plug from Z1 and also a new valve cover gasket and OEM fuel line from BikeBandit. I am going to order carb boot o-rings also. My plan of attack now is to replace the valve cover gasket and adjust the valves.

As soon as I can source an exhaust system I should be able to take it to the shop and get it tuned.

Any one have a used system that they want to get rid of?

I have a question about the starter block off plug also. The plug is made by APE racing. I didnt do much research before hand on buying it. I bought a vented one without realizing there was a choice for a non vented plug. Should I run a hose from the plug to a catch can or would a simple breather filter suffice? Or should I just put a vacuum cap on the end of the plug and clamp it down? The starter is removed due to my issue with the starter clutch not disengaging. I seriously don't think I can run with an electric starter due to the crank surface that the starter clutch rides on being damaged. So I went ahead and bought the plug so I can at least run the bike without oil pouring out of the starter hole.

If any one has used one of these and had any tips I would be greatly appreciative.
 
New pics. Not too different but things are taking shape.

2011-02-12_16-32-09_871.jpg


2011-02-12_16-31-59_823.jpg


2011-02-12_16-31-25_816.jpg


2011-02-12_16-30-53_417.jpg


2011-02-12_16-30-38_781.jpg


I now have a headlight, proper gauges, and all the bits to make it run. I put my exhaust on today and I ordered supplies to make SS brake lines also. All I have left now is cosmetics, tires, and rebuilding the brake cylinders.

For some reason the quality of the pics went through pretty crappy. They looked good on photobucket.
 
Last edited:
Sorry it took me so long to find your thread but I am glad I found todays post.
Congrats to you for saving this bike, keep up the good work!
 
Oh and these pictures were taken right after I had to pick that 600 pound beast off of myself. The motor didn't feel too good resting on my leg.
 
z33kyle said:
Oh and these pictures were taken right after I had to pick that 600 pound beast off of myself. The motor didn't feel too good resting on my leg.
Click to expand...
At least you weren't at a major intersection, 3:00 am, drunk as hell, watching the signal light change from red to green hopeing nobody was coming to run you over.... cuz that sucks!
But hey that was '82, things were different then (right?) :rolleyes:
 
Update: 6May2011

DSCN0336-1.jpg


I have been busy working but not busy posting. Here is the mock up of my freshly painted swingarm and rear caliper.



All the brake components have been rebuilt. The only piece lacking of the braking system is the rear stainless braided line.



This is how she sits right now in her cluttered corner of the garage. My fiance bought me new tires so I am cleaning the wheels up right now getting ready to take her to a tire shop.

Last month the bike was trailered to my buddy's shop and we put on the new points, and did some troubleshooting. She now starts up on the first kick. We tried to sync the carbs but of course there were intake boot issues.

Two out of four boots were sealed, but after removing all four they were all nasty.



I don't have to tell you which boots are the new ones. As soon as I get my new tires on the bike, it will get trailered back down to my buddy's shop to get the carbs synced.

Tail has changed too. Fiberglassing was alot of trouble. Factory fairing from another '77 model. The tail is just resting on the back. The tail will set a few more inches back and raked up slightly.



Much more to come, school is out for the semester so I will have a lot more free time.
 


Like the look you got going on! This is gonna be so stinkin COOL
 
i used my original tailpiece, also. it worked out pretty good. The way mine is sitting right now, tank & tail are satin black. I took the flyscreen off, put on a chrome headlight bucket, & installed clip-ons (no new pix yet). I have a build thread going on over in the "appearance" section.
Good Luck!!
 
huzier said:
i used my original tailpiece, also. it worked out pretty good. The way mine is sitting right now, tank & tail are satin black. I took the flyscreen off, put on a chrome headlight bucket, & installed clip-ons (no new pix yet). I have a build thread going on over in the "appearance" section.
Good Luck!!
Click to expand...

Excellent, I love the way the factory tail piece looks with a lower seat. the other was too much fabrication for me. I will eventually get clip-ons but for right now I will put up with the clubmans.

Thanks for all the comments guys.
 
Looks great...be interesting to see the rest of the build!



DDM
 
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