78 GS 750 Rebuild

[Sam 78 GS750]

Bit of progress last night, and a bit of a snag...
Got the pistons in, and put a cross hatch on the cylinders. I ripped the base gasket trying to get it put together though, so engine assembly is on hold until a new one comes in. I ordered 2 just in case.

 

[Sam 78 GS750]

Made some really good progress lately. Engine's almost ready to go back in the frame, and I almost have a rolling chassis. Just need to pick up my wheels from the shop where the tires are getting installed. Super excited right now! :eagerness:

Cylinders masked off for deglaze/cross hatch.
20180112_175308 by samL9, on Flickr

Engine as she sits now. 2nd attempt on installing cylinders and head. Ripped the base gasket on the 1st attempt... Had to wait close to 3 weeks for an "in stock" gasket to ship. Showed as "preparing order" the whole time. 2nd order in a row from Partzilla where this happened. I need to find a new parts source. It's ok, because I just shifted my focus to the chassis until it came in, but it's annoying. Don't list something as in stock and "ships within 24 hours" if that's not the case. Either way, I definitely could have used 5 more hands to drops the cylinders on the pistons. :nightmare:
20180127_180517 by samL9, on Flickr

20180127_180533 by samL9, on Flickr

...and the frame. I'm finding myself doing a lot of sanding, filing, and thread chasing to get stuff to fit right with the powder coat, but it is what it is.
20180127_173059 by samL9, on Flickr

In other news, I went to John at Cycle Passions for the tire mounting on the recommendation from a couple of members here. He hasn't even done the work yet, and I'm already super thrilled with him. He handled my rims like they were precious diamonds or fragile and rare dinosaur eggs. He took one look at them and knew the work that I put into getting them to look like they do. I'll be going to John for anything I can't/won't/don't have the tools to do myself.

 

[LarsKroghStea]

Great work

 

[Sam 78 GS750]

Thanks Lars. It's a labor of love...

 

[Sam 78 GS750]

Have a few new pics...

For the engine, got the cams in and a few more bits and pieces on there...

[/URL]20180215_182026 by samL9, on Flickr[/IMG]

I'll be pulling the cam chain tensioner off at some point and polishing it up a bit.

I think I got the valve timing right, but the 3 arrow looks off. Was hoping some ppl could verify. Below pics were taken at 1-4 TDC

Exhaust Cam
20180215_181903 by samL9, on Flickr
Hard to see from this angle, but at eye level the #1 arrow is parallel and flush with the gasket surface.

Intake Cam
20180215_181820 by samL9, on Flickr
This is 20 pins, counted and recounted, and then recounted again... It looks to be advanced, but...

The notches on the cam ends line up perfectly...
20180215_181951 by samL9, on Flickr

I think I'm good, no strange noises or resistance when turning over by hand...

 

[Sam 78 GS750]

...aaaaand we have a rolling chassis!

20180215_182549 by samL9, on Flickr

 

[Guest]

Looking really good!

 

[Sam 78 GS750]

A few detail pics...

Front End
20180215_182459 by samL9, on Flickr

Rebuilt and polished the forks, polished and painted the wheels. Masking those rims was tedious to say the least...also surfaced and painted the rotors, and zinc plated all the old nasty hardware. Tires are Avon Roadriders.



and the rear.
20180215_182353 by samL9, on Flickr

Same stuff as the front as far as paint/polish. Also disassembled and repainted the shocks, and soaked the springs in some metal rescue...



A closer look at the zinc plating on the hardware (chain adjusters, axle, axle nut, etc.)
20180215_182247 by samL9, on Flickr



Center Stand. Zinc plating on the spring came out pretty good, I think...
20180215_182428 by samL9, on Flickr

Getting that spring on was interesting. :grief:


and another angle on the whole shebang.
20180215_182156 by samL9, on Flickr

 

[Sam 78 GS750]

Looking really good!

Thanks Steve. I'm starting to get my second wind on the build since it's actually starting to look like a bike again.

 

[GSXR7ED]

Great rebuild! Thanks for the pics and narrative. You'll be enjoying the fruits of your labor soon!


Ed

 

[NickyGS750]

Very nice build and process! Going to be a beautiful bike! Cant wait to see more!

 

[Sam 78 GS750]

Thanks, Ed and Nicky. It's definitely coming along. Got the engine in last night with the help of a couple of strong friends, and my wife and sister were johnny on the spot with the bolts and such..... I'll post a few pics later tonight.

 

[Sam 78 GS750]

So finally getting around to posting pics of the engine going in the frame...

Wrapping the frame in pipe insulation to protect the powder
Eng1 by samL9, on Flickr


...and wrapping up the engine
Eng2 by samL9, on Flickr


Not many pics of the 'in progress' but this is it finally in
Eng3 by samL9, on Flickr


She's just about ready to take for a ride...nthego:
Eng4 by samL9, on Flickr

 

[Sam 78 GS750]

A bit more stuff done since then...


Got the chain on
20180304_115354 by samL9, on Flickr


and so I buttoned this side up
20180304_115420 by samL9, on Flickr


a few more pics...ignore the greasy fingerprint smudges on the polished covers, etc.
20180304_115538 by samL9, on Flickr

20180304_115445 by samL9, on Flickr

20180304_115310 by samL9, on Flickr

20180304_115222 by samL9, on Flickr


...up next
20180304_115658 by samL9, on Flickr

 

[Sam 78 GS750]

Here's us doing our best impersonation of the Keystone Cops trying to get that first bolt to line up...

https://flic.kr/p/24Tb7b4

 

[NickyGS750]

Killer work on this project. Clean build... definitely lots of inspiration for me. I cannot wait till im at this stage... Im still cleaning and prep'n parts.

 

[RogerW]

Nice work Sam ! Are those stock handlebars?

 

[Guest]

Nice work. :encouragement:
I hadn?t thought of using pipe insulation to protect the powder coat. Will be doing the same soon.

 

[Sam 78 GS750]

Killer work on this project. Clean build... definitely lots of inspiration for me. I cannot wait till im at this stage... Im still cleaning and prep'n parts.

I've been keeping an eye on your build thread, Nicky. At the rate you're going, you may just finish before I do... Since you're cleaning as you disassemble, and looks like you're super organized... When you go to put everything back together you'll thank yourself, trust me.

 

[Sam 78 GS750]

Nice work Sam ! Are those stock handlebars?

I'm not entirely sure. They're the ones that were on the bike when I bought it around '08 or '09. Someone else on the site may be able to speak better to what's stock on this bike. I found out after riding the bike for a few years that the forks are from an '82 GS650, so the bars might be also...