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GS750: White Orphan Baby build

  • Thread starter Thread starter DannyMotor
  • Start date Start date
I no longer hate wiring... I just wish it were less time consuming.

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Going to add a few grounds... one from the main harness to the battery, to the motor, and possibly another up under the tank if needed. Definitely need to wire the battery box plate to the frame due to the rubber mounts.

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Didn't realize there was a gear indicator!!!! That's pretty badass! I tested the wiring from the pickup on the case to the connector, and everything is sound... there's just no way to actually "test" the indicator to see if it even lights up/works anymore. When it was on the bike it didn't light... but the grounds were so bad and the wiring connectors were so corroded it could've just been the conditions.

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Ripping the gauges apart was fun. Debating on color-matching the black casing to the body color... possibly aluminum like the engine cases... it all depends on what color I'm going to do the trees... possibly polished top, black or gold bottom, we'll see.


On a side note... HOW THE HELL do you remove the gauge from the orange plastic casing??? Does the black rim/glass piece screw off or is it glued in-place? I want to clean the glass and re-paint the "orange" on the needles. Possibly play with a different gauge face.
 
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Finished my wiring. Got new wrap on them, soldered up a new power lead to the starter solenoid, and cleaned EVERY SINGLE connection by soaking in vinegar and then coating with some di-electric grease.

Came out pretty good! Just hoping it fits back where I found it!

Currently: Painting the battery box, working out some more polishing bits, and trying to break the race off the bottom of the steering head.
 
Just ordered headstock bearings. hopefully next weekend we can get a rolling chassis.
 
Alrighty, so... spent most of the day finishing up all the polishing bits:

Top Triple
Mag Cover
Points Cover
Clutch Cover
Clutch Case
Cam Breather

I think that's it... total!

I ended up using wrinkle-black paint on the chain cover, due to it being a gross area and honestly thinking that it'd be TOO shiny... which I don't really want. Once I get the new emblems for the motor it should tone down the polishing by a lot.

Finished up with the carburetors finally... Thanks to CycleORings for the bolts and all the o-rings needed to get the boots and carbs back into operational order.

Did a bench-balance on all of the carbs.. so now they all "click" shut at the same time... of course that doesn't matter once the idle screw was re-installed, but it's a better starting point.

I had my AF screws set at 1.5 turns out, and the larger "SET FROM FACTORY DO NOT TOUCH" screw by the bottom bowls set to 2 full turns out. So... they're balanced as much as possible before gas gets to them.

Started more prep and paint today. Got all of the polished bits coated in 3 coats of lacquer and have the exhaust stripped very near to bare metal. Battery box, and engine brackets are next as well as front discs as they're already off the hubs.

So, here's the plan for the rest of the chassis:

Fork Seals, Lower forks painted flat black.
Exhaust painted flat black.
Battery Box painted gloss black.
Air-Box painted flat black.
Front and Rear disc centers painted gold.
Engine brackets painted gold.
Lower triple tree painted gold.
Rear swingarm painted aluminum.
Rear brake stay painted black.
Front and rear brakes gloss black.
Wheels... on the fence.
Sprocket, aluminum (cleaned up).
Rear shocks... either clean up what I've got or invest in new... on the fence.
Headlight, kick-stand, center-stand - gloss black.
Gauge cluster, peg mounts, flat black.

Then it should be the home stretch and I can focus on rolling chassis, getting it turned over, and working on the tins.

Things left to buy:
- Rear Motor Mount (located)
- GS750L, or other leading-fork axle (unknown)
- Marker lights (something aftermarket)
- Bolts... lots and lots of bolts.
- Paint.
- Possibly tires... but what I have are OK for now.

I'm so excited to finally see the bike taking shape. Each little bit I bolt on puts a bigger and bigger smile on my face. It's not perfect... and it won't win any shows... but it's saved... unless it doesn't start or I cant locate a title... in which case I'll have one hell of a lawn-ornament.... maybe I'll invest in lawn gnomes.
 
Coming along nicely there, keep it up.
To remove the gauges, you need to take a small flat screw driver and carefully pry the bezel off, you will see it is crimped around the glass and the casing.
Or you can take a dremel with a cut off wheel and cut just below the bezzle all the way around the casing and split it in two and glue it back together afterwards again, there is a thread on it here somewhere, just do a search.
Keep the updates coming.
 
Started fiddling with the brakes... Painted up the slotted calipers and got the old solid lumps off there.

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Gotta get to work on the wheels and swingarm next.

Waiting on a few parts before I can start finish wiring and get the motor sealed up.
 
Interesting. :-k
The 750 engines have the clutch lever on the oil fill side of the bike and do not have a two-piece chain-gaurd cover.
Do you also have 6 gears?

I always thought that the 550 and 650 cylinder spacing was closer and you couldn't use 750 cylinder on those engines. :confused:

Eric
 
I stand corrected.
I just checked the parts fiche's.
It has been soooooo long since my 750 was stock. :o

I sure don't remember switching the clutch cable routing.

I will have to go look at the old engine tomorrow.

Eric
 
Last edited:
Haha... youve got me worried about you eric. too many years, too many suzukis... its beginning to mess with you. hahaha...
 
One more box of goodies on the way... then I can finally go buy bolts.

Where on earth sells Stainless Allen bolts long enough to fit the chain cover and the clutch cover??? I can't find them at any local hardware stores...
 
7981GS said:
If by chain cover you mean the cam cover, try these guys: http://www.ebay.com/itm/23073190371...AX:IT&_trksid=p3984.m1438.l2649#ht_624wt_1165

As for the clutch cover and stator cover, etc. call Z1 they sell kits. ;)

Eric
Click to expand...


Nah, chain cover... the part I painted wrinkle black in the above pics. There's to stubby bolts that go inside the clutch mechanism, and then 3 really long ones... two on the bottom and one that goes between the chain.

The links you guys all provided in the other post should include them though... I hope. Haha.

I've checked ACE and Aubuchaun Hardware... they have a limited selection last time I went in.
 
Nother' box o-goodies :)

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Couldn't resist slapping on the motor emblems.

Got tach cable, gaskets for the cam chain adjuster, cam cover, cam cover breather, new tach drive rubber sleeve, spark plugs, new hose clamps for the carbs, new wire ties for the handlebars and a few little things... fork seals... rubber mounts for the side-covers... good stuff.
 
I can feel the end closing in for the chassis...

Got the swingarm taken care of. Had some extra "aluminum" color paint so I threw it on the swingarm and it looks pretty good! I just have to do some sanding and what-not to take care of some of the unsightly ripples from poor prep.. (yay me).

Then, I attacked the exhaust. Took FOREVER to prep the damn thing. It was HORRIBLY rusty, so it took a couple different 3M drill pads... a few hours... a couple of days... a few more hours... and then I tried to separate the downtubes from the rest of the can... Nope. Not gonna happen.

So then I tried to take out the baffle... took another hour, a screwdriver (RIP Stanley) and a chisel (RIP Chester).... and I got it out.

No picture of it... but it's kinda stupid. It's just 2 tubes, off-set, and welded together. No batting, no holes... nothing. I may want to re-engineer this so it's not insanely loud...

Then, FINALLY... I got to paint the damn thing. 4 coats of VHT Flame-Proof flat-black, and then took a heat gun, crammed it up each one of the inlet pipes and let it sit there until the pipes started to smoke. Nice and cured.

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