My new project thread: 78' GS750

[Charlie G]

Nice pictures by the water! Looks great.

cg

 

[Spiff]

Sooo, haven't done much with the GS since I put it in storage in fall... But I have gotten around to unscrewing the carbs and measure the diameter of the intake boot o-rings, which by the way where rock solid, and there was evidence of some sort of sealant that's been used...

So now I think I'll contact cycleorings and get the orings for the carbs and intake boots so I can get the carbs up to shape

 

[Spiff]

Today's news: In trying to get the bike properly tuned up and resolve the hard to start when cold issue, attention has now turned to my valves
I have also received my o-rings for the carbs and I'm only missing the fuel bowl gasket before I start to tear them down... But back to valves!

I tried to check the clearances but the only feeler gauge I had didn't go any lower than .05mm and increased in .05 steps... On some valves I didn't get the .05 in and on other valves I could get the .10 and on one even the .15 blade. I also don't have the valve tool so I don't know what size shims are in there, therefore I'm now ordering a new feeler gauge set and a valve shim tool so I can figure out what I have and what to order...

Another question, how much work is involved in replacing the head gasket when the bike is this much dismantled ?

 

[Spiff]

Valve shim tool, feeler gauge set(0.02-1.0mm), fuel bowl gaskets, valve cover gasket and a new head gasket ordered. eBay <3
Now I'm just wondering if I should go for some 10:1 comp pistons too while I'm at it

 

[Guest]

Where the hell do you get a feeler gauge set that small? I need one

 

[Spiff]

Where the hell do you get a feeler gauge set that small? I need one

Hongkong obviously

search ebay for "thickness gauge metric" or something like that and this should pop up http://www.ebay.com/itm/New-0-02-To...262?pt=LH_DefaultDomain_0&hash=item5d3922d79e

 

[Guest]

Hongkong obviously

search ebay for "thickness gauge metric" or something like that and this should pop up http://www.ebay.com/itm/New-0-02-To...262?pt=LH_DefaultDomain_0&hash=item5d3922d79e

Thanks for the heads up but the ship time is waaaaayyyyyy long. March 15? Wow! I'll probably order a set though...

 

[Guest]

You could have the head and base gaskets replaced in a day maybe two if you're slow like me as long as everything goes ok. If you're taking the top end apart you mights as well put in new valve oil seals though, they're cheap as heck but it will take you a few hours to do and you will have to make a cheap tool out of a C-clamp and some pvc piping, easy to do though. Just so you know if you're replacing the head gasket you had better do the base gasket as well, you're guaranteed to disturb it and it would be a shame to do all that work only to have to do it over. And remember OEM for both gaskets and all the o-rings in the top end as well.

 

[Spiff]

Thanks for the heads up but the ship time is waaaaayyyyyy long. March 15? Wow! I'll probably order a set though...

Where do you get that from? Can't find that anywhere, anyway there are several other sellers selling these

Base gasket? Are you talking about the gasket between the crank case and the cylinder block?
Because I have been thinking of repainting the block and head since they're badly chipped...
It's a liquid gasket right?

 

[Guest]

yes the base gasket is the one between the crankcase and cylinder block. It's definitely not liquid, not exactly sure what it's made of but it's a paper 'like' material, someone will chime in one what it's made of. You can see it on any parts fiche.

 

[Spiff]

I see, I've read the service manual wrong then! Another gasket to order then, thanks for the heads up

 

[Spiff]

Oh what have you done!

So what started out as a carb overhaul ended up as a tear down
Forks and swingarm will be next to be disassembled and then sandblasting and powdercoating

Full of surprises; left side engine mount is broken, cracked right off...

Will try to get it welded but I'm guessing this is somekind of a AlMn og AlSi alloy and therefore will be a pita to get sorted....
Electrical is also fun! What happened to the stock connector? And why do I have seven leads coming out of the gearbox when there should only be six??

 

[Charlie G]

OH, that's not good!

cg

 

[Spiff]

Got my valve shim tool this weekend, so today I have checked clearances and figured out what shims I have...

Swapped two shims on the exhaust side but I'm in need of three shims on the intake side to bring them in to spec. So all in all four valves where too tight, and one was too loose.


I've also been in touch with a small company that does sandblasting and paint. I removed the rear wheel and swingarm today, only front forks, seat and rear fairing plus electrical to go now.
This engine is dirty and ugly!

 

[Spiff]

Went to a motorcycle show this weekend and found this mint GS750 on the Classic Suzuki Club of Norway's display, hopefully my engine can look as good as this when I'm done!

I also spent some time looking at the luggage rack and snapped a close up of it and I will try to copy this with round bar steel.

 

[Spiff]

So here's a rundown of what has happened since the last post:
When it comes to the GS, NOTHING!
December 2012 I bought a 2012 650 V-strom, so the GS wasn't exactly prioritised, I also have an old Datsun 280Z which needed alot of attention. And then there's my 2 year old boy, who also wants some attention and me and my girl are working completely different shifts so spare time is scarce...
Realising I don't have time for all of this I sold the V-strom, spent the money on a turboengine swap in the Datsun amongst other things and now I need to get the GS back on the road.
I can't bear the thought of facing next years spring/summer without a motorcycle....

So Recently I came across a Honda CB1100R fairing from a motorcycle wrecker, bought it. Along with clip-on bars, a gsx plastic front fender(because chrome and a painted fairing ain't gonna look so cool..) and more importantly; an engine gasket kit,a new clutch cable and some other necessities.
If anyone wonders, here is the fairing:
http://m.finn.no/bap/forsale/ad.html?finnkode=40898766&ov=m

mounted on a gs it'll look something like this:
http://www.finn.no/finn/mc/used/vie...2/2/vertical-3/15/2/295/716/52_1629883708.jpg

Other plans are rearsets and modifying the rear fairing so that I can move the rear light back and into the fairing itself. Frenching I believe is the term. Low profile indicators to clean it up and some new gauges that WORKS!

 

[Spiff]

Went shopping this weekend :

From this

Bought here :

Bikes and parts EVERYWHERE! Including the basement, an outhouse and a garage! Only narrow pathways to get from one end to the other
If only my fairing and other parts would come now so I can get started!

 

[T8erbug]

So here's a rundown of what has happened since the last post:
When it comes to the GS, NOTHING!
December 2012 I bought a 2012 650 V-strom, so the GS wasn't exactly prioritised, I also have an old Datsun 280Z which needed alot of attention. And then there's my 2 year old boy, who also wants some attention and me and my girl are working completely different shifts so spare time is scarce...
Realising I don't have time for all of this I sold the V-strom, spent the money on a turboengine swap in the Datsun amongst other things and now I need to get the GS back on the road.
I can't bear the thought of facing next years spring/summer without a motorcycle....

So Recently I came across a Honda CB1100R fairing from a motorcycle wrecker, bought it. Along with clip-on bars, a gsx plastic front fender(because chrome and a painted fairing ain't gonna look so cool..) and more importantly; an engine gasket kit,a new clutch cable and some other necessities.
If anyone wonders, here is the fairing:
http://m.finn.no/bap/forsale/ad.html?finnkode=40898766&ov=m

mounted on a gs it'll look something like this:
http://www.finn.no/finn/mc/used/vie...2/2/vertical-3/15/2/295/716/52_1629883708.jpg

Other plans are rearsets and modifying the rear fairing so that I can move the rear light back and into the fairing itself. Frenching I believe is the term. Low profile indicators to clean it up and some new gauges that WORKS!

Excited to see your build get going. Post some pics of your Z!

 

[Spiff]

Getting pretty excited myself to be honest! Got a mail from the motorcycle breaker that the fairing and parts are on the way so should be able to get going on the build this weekend or next week hopefully

I haven't got a project thread on the datsun anywhere but I have some vidoes on youtube:
https://www.youtube.com/user/salkcin86/videos

Here it is at my friends house, we where going to a classic car meet

 

[Spiff]

Mounted clipons today and did som test fitting and mockup of the fairing and rearsets. I think I need to get the engine back in the frame to position everything correctly. Instruments will be removed in favor of 2 smaller 2,5" instruments. We also thought about making a bracket for my mobile/gps where the old handlebar brackets are...