81 GS750E garage rebuild thread...

[PsychoRallye]

Dont laugh, but I just bought a "ding king" at Pep Boys for $20. It's not perfect, but most of the dent in the tank is GONE !
The gunk in the photo is some glue residue from the ding king - I just haven't cleaned it off yet. Pretty damn good! Took off a tiny bit of paint, but I don't care since I'm going to repaint anyway... Check it out! You can look in a previous post for the other (pre-ding-king) photo...

WOW...

 

[Hoosier Daddy]

I am impressed! I got one of those Ding-King's for Christmas when they first came out and have never taken it out of the box! Wonder where it is....

 

[PsychoRallye]

Hi guys- silly question, but head gaskets... since I've heard such negative things about the Athena I was going to use Suzuki...
Besides creases/poor storage is there anything to worry about if I use NOS vs current dealer stock?

Also, I see a number of 11141-45402 gaskets around but according to Babbitt's it should be a 11141-45401 (replaced by 11141-45410)... does anyone know the differences between the three? They're all GS750s.. not sure on type tho.

Thanks...

 

[PsychoRallye]

Hi guys... LONG time!! Sorry about that. I was sick, then the holidays, then I was REALLY sick. Now I'm finally getting back into the swing of things. In the time I've been gone, I sent the frame out for powdercoat and got it back. I took a few photos and added them to my Photo album .. Link to the album here

Will start taking more photos. I'm hoping to get the wiring harness back in the frame this weekend... but I'm an idiot, and I didn't take enough photos of the bike pre-full-disassemble... does anyone have links to something showing wiring routing? Some is obvious, some... damned if I remember LOL



For example, where does the horn get mounted? hahaha...

And of course, me being a bonebrain, I forgot to get a few pieces powdercoated. Back to the powdercoater I go.. for example, the top of the triple-tree, the battery box, and I messed up the rear swing arm putting the shock bushings back in, so back it goes too. D'OH!

This is the color I picked for the frame... thoughts?? Hope it works well with the light blue for the

 

[laserred97gt]

Wow.

I like the color. Should do the tank that color too!

 

[PsychoRallye]

Long time.. again!!

Long time.. again!!

Well, so life has been unkind - I've been sick a few more times - moved - etc... so the bike has been gathering dust.

So.. not anymore. Spring is coming!

I had a local shop polish the engine covers for me... finished my crappy paint job on the body (it's a five footer), and am in the middle of wiring...

The bike doesnt "do anything".

Let me explain. Fully charged battery (sure of it, I recharged it and it's fairly new).

Battery has a - to the engine. The Positive goes to the fuse box and to the starter solenoid (see the pics I hope to post).

To be sure the electrics are well grounded, I also put lugs to the Rectifier, Starter Solenoid and Fuse box (right side) to the - battery terminal.. because I wasnt sure what effect the powdercoated everything would have.

I'm pretty sure I must have wired something wrong.. and the Clymer manual is er.. less than useful.

Ok.. so the OIL PRESSURE and NEUTRAL lights on the dash come on when you switch the key on. I looked at the fuses (and tested them electrically) - they all are fine.. and the bottom 3 switch when the key switches..

However, no seeming effect from the KILL switch.. it looks like the YEL/GRN wire has -12V (huh?) on it. See the pic of the connector in the headlight box.

No lights work (headlight hi or lo, turn signals, running lights, cluster lights) and the starter doesnt bump nor does the horn work.

If I short the two sides of the starter solenoid together it does turn the starter. It's been so long since I heard the starter (hahaha!) I don't remember if it sounds OK or not - but it's definitely functional.

So.. what am I missing? Thoughts?? I know it's hard, but I'm looking for ideas...

Oh by the way, what stops the chain from hitting the center stand? See the photo... not that you need it to answer that I hope!


Thanks!!

Why does the chain hit the centerstand? Is it on upside down? Am I missing a standoff or something?

This is the starter solenoid. The black wire goes to the starter.. the red wire goes the the BATT + terminal. The YEL/GRN wire goes to the kill switch, as far as I can tell.

Kill switch connector. The Grn/Yel has -12V from what I can tell. Huh?

 

[PsychoRallye]

Oh, somehow I broke one of the shock top caps - the thing with the schrader valve on it. Anyone have one, including the schrader valve?

 

[hampshirehog]

Your centre stand hits the chain because you haven't got the exhaust fitted yet - there's a bump stop that does the job on your exhaust.

 

[PsychoRallye]

Your centre stand hits the chain because you haven't got the exhaust fitted yet - there's a bump stop that does the job on your exhaust.

Knew there had to be some easy explanation there haha thanks..

Still wondering on the wiring though... if anyone else can help.

 

[PsychoRallye]

So I figured out a little more... there was a ground on the main body harness which was not making good contact (because of powdercoat). I moved it to the - batt connection...

I also had a miswire in the starter button.. that was an e-z fix.

So now the kill works, so does the starter button (but all it does is click - maybe my battery is toast).

The rear brake light switch works, so does the headlight... cool!

No turn signals yet though. Can anyone tell me, have they had luck wiring in LED turn signals? The 2 contact relay that was stock on the bike doesnt match the 3 contact one that I got which is an LED turn signal relay box... i'll search a little...

She's starting to look like a bike!!!

 

[PsychoRallye]

So hopefully someone will have some input here... I'm unhappy with the front end and at least want to CONSIDER the idea of a front end swap with a more modern one with more modern calipers.

If I want to swap the whole triple tree, calipers, etc - just keep the handlebars and controls... what years of GSXR (or other bikes) should i be looking at? I'm kinda lost on how to start. Not just the bearing sizes have to match, but the height has to be about right also no? I mean - I know the new tree would possibly have a different tire on it so maybe it's the aggregate of the two.

Well anyway.. I searched a bit but nobody's written a "how to" for dunces like me

Any advice? Threads I can look at? Webpages to reference?

 

[hampshirehog]

If it's the brakes you're worried about don't. Your bike has the best calipers fitted to any of the GS line. If they're not working well then take a look at them.

If you're still not happy have a look at Salty Monk's caliper conversion using twinpots from a Kawasaki.

 

[PsychoRallye]

Thanks for the reply. It's actually not the brakes at all. I don't really like the suspension feel. Was wondering if something more modern with an antidive capability (or whatever it's called) would be nice... more reactive. Of course, to your point, I'd like one that I could bolt my brake calipers right onto (probably not going to happen) and even more preferably, keep the same speedo drive...

Also, for you wiring types out there..

I have the stock turn signal relay. I've replaced the turn signals with LEDs. As expected, the LEDs do not draw enough to "flash" the signals but do function as expected otherwise, including the cluster turning on.

So, I got an eBay LED turn signal relay- same connections with an "E" (for GND I assume) - so I connect B & L to the stock connector (same configuration) and E to GND... but the turn signals don't even light up. Not even the cluster indication.

I'd hate to use a load resistor. Those things are a stupid workaround and frickin hot. Do I have bum cheapo eBay relays (tried 2), or am I missing something? Like the interplay between the cluster signal indicators?

Thanks all..

 

[PsychoRallye]

She looks nice now doesn't she? Ran her today for the first time in two years. Started right up.. Doesnt idle yet, but choked up was fine. Oil pressure light went off.

1. Do I have to prime the oil pump at all with vaseline or anything or is the fact that the oil pressure light off enough?

2. What trick, if any, is there to the cam chain tensioner? How do I adjust it properly?

I still need to tighten the drive chain, and paint and install and bleed all three calipers. Any tips there?

What are your thoughts on the paint? I wanted to go old-school-ish-80s pale blue. Like the stripe? More photos when I have time.

Cheers!

ps - still having electrical issues with the signals, if you have any ideas that's over in the electrical forum...

 

[7981GS]

Bike looks great.
Where are your brakes???

Daniel

 

[cowboyup3371]

From Basscliff's page at the bottom, you'll find a link to this page http://www.bwringer.com/gs/ that contains instructions for rebuilding your tensioner. Happy reading.

 

[brslk]

She looks nice now doesn't she? Ran her today for the first time in two years. Started right up.. Doesnt idle yet, but choked up was fine. Oil pressure light went off.

1. Do I have to prime the oil pump at all with vaseline or anything or is the fact that the oil pressure light off enough?

2. What trick, if any, is there to the cam chain tensioner? How do I adjust it properly?

I still need to tighten the drive chain, and paint and install and bleed all three calipers. Any tips there?

What are your thoughts on the paint? I wanted to go old-school-ish-80s pale blue. Like the stripe? More photos when I have time.

Cheers!

ps - still having electrical issues with the signals, if you have any ideas that's over in the electrical forum...

Very pretty.

 

[BigRock]

From the photos it looks like you have the front wheel backwards.
My speedo gear is on the left.

 

[BigRock]

Oh and check the tire for the rotational arrow to make sure eerything is turning the right way.

 

[PsychoRallye]

Lol good point rock, I never even thought about it I was just guessing ahahaha!

Brakes are still in a box- the rear needs new seals and the fronts need a paint job...

Thanks for the tensioner link. I actually did a rebuild already using his info. I found the oil seal by the way, for like 1/2 the price of the Suzuki one - at a Nissan dealer. It's the tach oil gear from an 80s B series pickup HAHA. Now just to tension the chain

As for the oil pump, any thoughts from you guys on priming it? Was/is there any need to?

Thanks
Justin