78 GS750 engine overhaul on the Cheap!

[Cipher]

Beautiful job. Qwertyuiop

 

[Bobbys 94]

DOHC Suzuki etc? That's some third-grader you've got there!

Thank you. We used transparent high heat tape used for powder coating purpose. Bonds well and easy to trace the letters with an exacto knife.

 

[SamLack99]

As a newbie to the wonderful world of working on motorcycles...

...I've learned a great deal from the photos and words you've shared so far.

Thank you.

I'm in the process of getting a 1982 Suzuki GS750T back on the road. Having sorted the Tank and Carbs out, I had hoped a relatively simple valve check with replacement seals would allow me to see if I could get her to start.

Unfortunately, the paint job on the engine is flaking and peeling off in many places.

It's pressing all my buttons.

So I'm trying to get the old paint off. It is proving to be a very time-intensive job. Since methyl chloride​ has been removed from paint stripper here in the UK, I'm resorting to brass brushes, Dremel, and elbow grease.

It's taken me two sessions (in between life, work, family, etc) to strip about 1/4 of the cylinder. I think I might have started something I don't know how to finish!



Sorry for waffling.

My question is: How did you get the engine so clean whilst it was in the frame?

Any tips or advice on how to best get the paint off this engine is very much appreciated.

I look forward to more of your posts.

Thanks again.

Marcus

 

[Bobbys 94]

My question is: How did you get the engine so clean whilst it was in the frame?

Any tips or advice on how to best get the paint off this engine is very much appreciated.

I look forward to more of your posts.

Thanks again.

Marcus

Marcus,
I did remove the head and cylinder while the engine was still in the frame. My engine was not painted black it just had the factory silver which came off pretty easy with stripper and elbow grease. I think that in your case I would either remove the engine and get it vapor blasted or tear it down completely and work on the individual pieces one at a time. Either way, it's going to be a lot of work. It looks like you're committed now so keep up the good work.

 

[SamLack99]

Either way, it's going to be a lot of work. It looks like you're committed now so keep up the good work.

I don't mind hard work, as long as I haven't missed a smarter way of doing it.

Thanks for the confirmation =)

 

[Bobbys 94]

Decided on a color for the Cheap GS750 build. Pictured below is a FB Market place buy for $200. A 1977 GS750. The ad did not show the tank and side covers but when I arrived to pick it up he said he found a few extra parts that where in his closet. The tank is absolutely Pristine and free of any rust what so ever.
So the color will be Blue on my Cheap build.

 

[Bobbys 94]

The spoke wheels are also very nice as well as the instrument cluster and signals. The frame is what I purchased it for and I got a whole lot of Great components with the awesome frame.

 

[Bobbys 94]

The tank is beautiful and all original. Came with a factory Suzuki key that matches the ignition, gas tank lock and seat lock.

 

[MaurieG]

Marcus,
I did remove the head and cylinder while the engine was still in the frame. My engine was not painted black it just had the factory silver which came off pretty easy with stripper and elbow grease. I think that in your case I would either remove the engine and get it vapor blasted or tear it down completely and work on the individual pieces one at a time. Either way, it's going to be a lot of work. It looks like you're committed now so keep up the good work.

You mention 'Factory Paint' on the engine. I'm in the process of restoring my '78 750EC. I was led to believe the only part of the engine that came painted from the factory, was a crankcase half. Up to now, I've never found out which half that was! Can you, or anyone else following your build, enlighten me, please?

 

[Bobbys 94]

Not sure what the process was called "Back in the Day" but there was a process. The process of coating the surface of the cylinder, cases, cylinder head and valve cover to protect against corrosion. It can be removed with chemicals but it will still boil down to "Elbow Grease" at one point.

 

[rphillips]

That's interesting, I never heard only 1 half of eng. case was painted. Hope somebody may have more info.

 

[Bobbys 94]

The "Cheap" GS750 engine build just became "Not Cheap" GS750 engine build. Thanks to a member I now have a Weisco 850 kit for the 750. Along with many other rebuild pieces like:
APE valve springs
8 new valves
Complete OEM gasket set
Schuman valve guides
OEM Intake boots
20 new head bolts
Barnett fiber and steel clutch plates with clutch springs

You have to want to do this for "YOU/ME" because you'll never get what it's worth if you try to sell it. My intentions have never been to build this for resale to anyone. It keeps me busy and I learn something every day working on these projects.

I won't be starting the 850 kit until I'm done with my 1977 GS750 project shown below.

 

[Bobbys 94]

This is on my lift and ready to start the resto. I will be keeping this 1977 GS750 in stock configuration. After soaking the entire bike in about a gallon of WD40 over the past month this is what I have to work with now. I did have to buy all the engine side covers because they where all missing including the stator assembly. I did do a little hand polishing to them before I installed them. Now the tear down begins.
My goal is to replace anything that is wore out or in need of replacing due to old age. Complete carb rebuild, fork seals, all wheel bearings and seals, tires and tubes, triple tree bearings, all brake components

 

[Bobbys 94]

Left side of the GS750 just because

 

[Bobbys 94]

A couple token shots of the engine. It cleaned up very nicely.

 

[Bobbys 94]

Left side close up of the engine.

 

[Bobbys 94]

Got the GS running like new. Everything works as it should. Rode about 6 miles going through the gears and all felt pretty good for a 47-year-old machine. I plan on keeping this at least until my grandson shows interest and is worthy owning and riding this machine and the upkeep that goes with it.
The pic below shows how it looked after most of the general maintenance had been done and a good cleaning/polishing.

 

[Bobbys 94]

Pictured below is what I've begun to service on my GS.
Forks had little to no fluid in them and seals were dry and brittle. Front wheel bearings made some noticeable noise while riding. Rear hub/carrier felt warmer than it should have for only going 6 miles. So I did what everyone should do on a 47 +- year old machine that you plan on counting on for a safe and reliable ride "Every time"

 

[Bobbys 94]

Other side of my GS. Removed swingarm and it needed it, About 38 years ago! Swingarm needle brgs had only hard grease in them. Kinda like candle wax. No" Lubrification"
I rebuilt both brake master cylinders and both calipers. New brake pads and new front brake hoses. Dot 5 synthetic fluid.

 

[Bobbys 94]

Pic below shows the "3" different brands of bearings and to my knowledge, NSK was the bearing manufacturer of choice by most metric bike manufacturers, back in the day. Only one of my removed bearings is NSK, the front set is Turkish made and two of the rears are unknown manufacturer. The front brgs could not be turned by hand after the wheel was removed. One of the rear hub brgs was the same. The only NSK brg was the sprocket/carrier large brg. It's grease was also like candle wax.