1978 Suzuki GS750 project

[ValorSolo]

I'll be updating this daily, journal style.
This is my first bike. I've ridden tons, but never owned one.
I first thought about going cafe with it, but now I'm thinking semi-cafe.
This bike is a bit heavier than I wanted, but I can always trade down later on.

March 20, 2012
Day 1
Project Cost: $550

Today I purchased the bike and brought it home.
I haven't had much time to get a feel for what all it may be needing.

I've put up some pictures to illustrate the starting point of the project.

In one picture you can see the seat is in very poor condition.
Yet what you can't see is both hinges and the latch have broken off of the seat pan.
I pulled the seat cover off the pan and found a couple of other surprises.
The first was the foam was totally degraded and unusable.
The second surprise was a centipede running all over the place. I cut him in half and dropped him into my goldfish tank.
So I guess I'll be on eBay trying to find a new seat. I didn't like that double saddle seat, anyways.

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March 21, 2012
Day 2
Project Cost: $560

I removed, flushed and installed the gas tank.
When I put gas in it, I discovered a leak in the carburetor connecting tubes.
I then removed the tank again and the carbs.
I'll have to pick up some o-rings and what ever I need to clean the carbs.
I did some scrubbing on the motor until I could no longer see well enough to continue.
I'll have to finish that tomorrow before putting the carbs back on.
I'm gonna leave the air box off and install four pod air filters.

I've been charging the battery on 2 amp since yesterday.
Hopefully by tomorrow I will know if it takes a good charge.
I unhooked the charger this morning and it had enough to turn the motor and run the lights.
But the battery wasn't strong enough to start the bike.

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March 22, 2012
Day 3
Project Cost: $580

I've cleaned the carbs and reassembled them, a much easier task than I had expected.
I ordered a choke lifter and have to wait for it to arrive before mounting the carbs back on the bike.
No luck finding connector tubes, but was told to soak mine in brake fluid.
I let them soak for a few hours and they seem to fit tighter when I installed them.
Didn't have a lot of time left to do any more cleaning on the bike.

After another full day of charging the battery, it failed to take a full charge.
So I'll have to pick one up when I'm ready to fire the bike up. Another $50 gone.

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March 23, 2012
Day 4
Project Cost: $604.50

Slow day today. I really didn't do much on the bike.
I ordered a set of four pod filters on eBay for $24.50, a very good price.
These look just like the K&N filters that sell for $42 each.
I removed the windshield, tail and cargo rack.
The tail is cracked and needs repairing, if I decide to put it back on.
The windshield and cargo rack are staying off.

My nephew is a good automotive body and paint man.
I'm thinking about getting him to paint the tank and side panels.
Those damned flame decals have to go.

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March 24, 2012
Day 5
Project Cost: $648.55

No work done today. I had other things to do.

I found and bought the connector tubes, a much better replacement than the original tubes.
Those set me back another $44, but they'll pay for them selves over time, considering I never have to replace them again.
The tubes, filters and choke lifter should all arrive by the middle of next week.

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March 25, 2012
Day 6
Project Cost: $670.70

I ordered the o-rings for my carbs and boots.
I didn't do a proper job of cleaning my carbs the other day, so that's to do over.
I disassembled the carbs and have them ready for boiling.
Didn't find any lemon juice or even Pinesol, so I'll have to pick some up in the morning.
I removed the rear fender, inner and outer. I'm gonna leave them off.

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March 26, 2012
Day 7
Project Cost: $706.00

I boiled the carbs, twice, 30 minutes a piece, each time.
My bowl gaskets didn't fair so well and need replacing. Another delay.
Went to Advanced Auto and spent $30 on some paint. Now my funds are a little low.
Oh, my pods and connector tubes came today. Z1 has some fast shipping.
The choke lifter will be here tomorrow, and the o-rings should follow a day or two after.
I need to order those bowl gaskets tonight if I want to get everything by the end of the week.

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March 27, 2012
Day 8
Project Cost: $741.00

I painted my carbs, getting them ready for when the o-rings arrive.
I'll put up some pictures when I get them back together.

I won the seat on eBay. No other bids, so I got it for under $35. Not bad.
My choke lifter was a no-show, maybe it'll be here tomorrow. And the o-rings.
I'm not going to buy bowl gaskets, I'll just make some.

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March 28, 2012
Day 9
Project Cost: $741.00

I lightly painted my case and covers. I'll do a proper job of it after I get her running.
I didn't touch the valve cover as I'll be taking it off to adjust the valves when my money gets healthy.
I removed the crash bar to get access to some covers. I'm tempted to leave it off.

My choke lifter arrived, but it's the wrong one. Maybe it'll work and maybe it won't.
The o-rings are still not here. I'm pretty much ready for them now, so hopefully today will be the day.

This week will probable end the day to day updates of this thread.
A proper restore is more than I can afford all at one time.
I'll keep working at it in the future , but now my priority is getting the bike road ready.
I really want to ride this monster this weekend.
After I ride it, I'll better know how much I want to put into it.
This will determine if I fix it up to sell or fix it up to keep.

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[DannyMotor]

I've got a seat for a 750L if you want it. It's like brand new. I'm not using it on my current project.

Good find so far! I hope you don't plan on keeping the flame stickers... (even though they probably do add horsepower AND torque... )

 

[ValorSolo]

I've got a seat for a 750L if you want it. It's like brand new. I'm not using it on my current project.

I have a bid on eBay for one. Let's see what happens with it and I'll PM you and see if we can work something out.
And I appreciate the offer. I may get it from you even if I win the bid on eBay.

Good find so far! I hope you don't plan on keeping the flame stickers... (even though they probably do add horsepower AND torque... )

At the expense of the added power, the flames have to go.
It would be bad enough it they were all the same color, but who ever put them on, used four different colors of flames.
And there's a wolf decal on top of the tank that will be coming off, as well.

 

[steve murdoch]

Looks like a good candidate for a resto...those pipes look great.
The o-ring soak works in a pinch but i would get new ones before re-installing.
http://cycleorings.com/

 

[ValorSolo]

The pipes actually have a little damage from a lay down, but it doesn't show in the pictures.
The connector tubes have a sleeve on them instead of o-rings, I went ahead and ordered the replacement tubes from Z1.

 

[TheCafeKid]

The pipes actually have a little damage from a lay down, but it doesn't show in the pictures.
The connector tubes have a sleeve on them instead of o-rings, I went ahead and ordered the replacement tubes from Z1.

Better order some larger main jets for those pods too. The bike will run like complete ass without re-jetting for pods.

 

[ValorSolo]

How can I tell what size jets I have or need? I know very little about carbs.
I'm gonna have to learn how to adjust and re-sync them, as well.
But at least I have time to read up on that before my parts arrive.

One more thing. How do I determine what type 750 I have? Whether it be a 750L or 750E or whatever.
I looked on the frame plate, but most of it is rubbed off by poorly run wiring.

Oh and the vin on the title matches the frame but not the motor. Is that something to worry about?
I wouldn't think so, as motor swaps are pretty common.

 

[TheCafeKid]

How can I tell what size jets I have or need? I know very little about carbs.
I'm gonna have to learn how to adjust and re-sync them, as well.
But at least I have time to read up on that before my parts arrive.

One more thing. How do I determine what type 750 I have? Whether it be a 750L or 750E or whatever.
I looked on the frame plate, but most of it is rubbed off by poorly run wiring.

Oh and the vin on the title matches the frame but not the motor. Is that something to worry about?
I wouldn't think so, as motor swaps are pretty common.

What sort of intake and exhaust set up are you running?

As to the frame and engine numbers, they were never meant to match. I doubt there is a single GS on this board that has matching numbers. Frame was made and stamped with a VIN and sat on a shelf until it was needed, and then mated to a motor that might have been made weeks or months later.

 

[Big T]

1. How can I tell what size jets I have or need?
2.I know very little about carbs.
3.One more thing. How do I determine what type 750 I have? Whether it be a 750L or 750E or whatever.

1. The numbers are stamped on the jets and needles. What you need depends on what you do to your bike.
2. Um, you cleaned your carbs in one day? Did you follow the tutorial? Should take 3-4 days. Did you replace the O rings? You're either going to know a lot about carbs, or just give up with your plan.
3. Yours is a standard model. It doesn't have a letter designation. Since it's a 78, the year designation is C

BTW, those bargain pods are just going to give you headaches. Get the bike running with the airbox first, so you know how the bike should run. Then you can put the pods on and endlessly fiddle with the carbs from there.

BTW, 2 amps is too high a charging rate for your battery. Try .5 amp or even less on the new one

Did you get a Megawelcome? The Top 10 Common things? The Newbie mistakes?

 

[jwhelan65]

That is the fugliest seat I have ever seen..

 

[DannyMotor]

2. Um, you cleaned your carbs in one day? Did you follow the tutorial? Should take 3-4 days. Did you replace the O rings? You're either going to know a lot about carbs, or just give up with your plan.

Unless you have the parts handy, ordered the o-rings ahead of time, and boiled your carbs in 50/50 Lemon Juice and water for 30 minutes a piece... there's absolutely NO WAY to properly clean your carbs in one day.

Boiling them is the fastest and (in my own opinion) easiest way to get them 100% clean, 100% of the time.

 

[ValorSolo]

What sort of intake and exhaust set up are you running?

Everything is stock as far as I know.

As to the frame and engine numbers, they were never meant to match. I doubt there is a single GS on this board that has matching numbers. Frame was made and stamped with a VIN and sat on a shelf until it was needed, and then mated to a motor that might have been made weeks or months later.

That is logical.

2. Um, you cleaned your carbs in one day? Did you follow the tutorial? Should take 3-4 days. Did you replace the O rings?

It looked like the carbs had just been cleaned before I got it.
The o-rings and everything looked brand new and the inside was spotless, but I went over everything again. I followed a guide I had before joining here, but not the one from here.

You're either going to know a lot about carbs, or just give up with your plan.

I certainly won't be giving up, so I guess I'll have to learn.

3. Yours is a standard model. It doesn't have a letter designation. Since it's a 78, the year designation is C

BTW, those bargain pods are just going to give you headaches. Get the bike running with the airbox first, so you know how the bike should run. Then you can put the pods on and endlessly fiddle with the carbs from there.

Good info and suggestions.

BTW, 2 amps is too high a charging rate for your battery. Try .5 amp or even less on the new one

The guy that sold me the bike said it needed a new battery. But I had to test this one anyways. NAPA has one for $50 in stock.

Did you get a Megawelcome? The Top 10 Common things? The Newbie mistakes?

I did. I looked it over, but I'll study it a little harder this time.

That is the fugliest seat I have ever seen..

I totally agree. Even if it didn't need replacing, I wouldn't keep it on the bike.
I'm going to try and salvage the pan and fabricate a custom seat.

Danny I was typing when you posted so I missed that.
I'll throw my guide away and do it proper as you have stated.
No problem, the carbs are still off the bike while I'm waiting for other parts.

Thanks for helping me avoid future issues.

 

[ValorSolo]

Are these the bowl gaskets that I need?
http://www.z1enterprises.com/Float-Bowl-Gasket--29mm-smoothbore-76.aspx

I looked my bike up on the chart from this link:
http://members.dslextreme.com/users/bikecliff/images/carbspec_float_height.html
It says my carbs are vm26ss. Is that correct?
I know it is a VM carb and not the CV.

 

[ValorSolo]

Well I won't be riding this weekend or anytime soon.
This project just hit a major snag.
My o-rings arrived today and as I attempted to rebuild carb #1, I had one of the jets break off inside the body.
I wasn't torquing it hard, just screwing it in. It snapped off suddenly, not in a bind.
My guess is the boiling in lemon juice made it brittle.

Now I have to step back and think of what to do next.
I'm too leery of a repeat to try to rebuild the other three carbs.
I think I'll buy new bodies and jets and whatever else I may need.

 

[ValorSolo]

Project update.
I'm getting a set of carbs from TheCafeKid.
I've been learning how to polish aluminum and should have all covers off, polished and back on when the carbs get here.
My petcock needs replacing, but I need to wait for some funds.
I've been wanting to strip the paint off the tank and side covers and at least get a coat of primer on them.
And then after all that I can turn my focus on r/r, battery and wiring. Or frame first, then electrical.

 

[TheCafeKid]

Project update.
I'm getting a set of carbs from TheCafeKid.
I've been learning how to polish aluminum and should have all covers off, polished and back on when the carbs get here.
My petcock needs replacing, but I need to wait for some funds.
I've been wanting to strip the paint off the tank and side covers and at least get a coat of primer on them.
And then after all that I can turn my focus on r/r, battery and wiring. Or frame first, then electrical.

Carbies are coming along beautifully. It's honestly a nice change of pace from the CV carbs id been doing so much recently. I haven't rebuilt a set of VMs in a couple years. Took me a minute to remember how to get the rack apart but other than that it was almost like riding a bike

Got the second two in the dip today, polished bowls and tops, and brass theyre going to look darn nice

 

[ValorSolo]

That's great. I have no doubt you're doing an excellent job.
Getting the carbs off the rack took me a few minutes to figure out.
But now that I've done it, I know how to do it for the next time.
I know very little about carbs, but those VM carbs were much simpler than I had expected.
Or at least not as many parts as I was expecting.

 

[GateKeeper]

Carbies are coming along beautifully. It's honestly a nice change of pace from the CV carbs id been doing so much recently. I haven't rebuilt a set of VMs in a couple years. Took me a minute to remember how to get the rack apart but other than that it was almost like riding a bike

Got the second two in the dip today, polished bowls and tops, and brass theyre going to look darn nice

Hey there now....where are the progress pictures.....????

don't be holding out on us....

 

[ValorSolo]

I'm certainly not opposed to pictures. Let us see em. lol
But only if you have time, I don't want to stand in the way of progress.

Back on topic, I pulled the points cover off and did a ton of sanding.
I had to do away with the DOHC decal. It was brutally ruined in a lay down.
I left the decal area a little rough for when I get around to a replacement.

I started bogging my 1/3 hp grinder while buffing the cover, so I wasn't able to apply enough pressure to do the job.
So I grabbed my 30 year old, 3/4 hp, 8" grinder out of hiding to see if it still works.
I ran a power test on it and it sounded like a brand new one. Now time to get the wheel nuts off.
Also, my brother is bringing me some 8" or 10" sisal wheels in the morning.
I should be able to kick ass tomorrow.

 

[ValorSolo]

Woohoo! My seat arrived today. It's in great shape, too.
Not as stylish as some, but way better than that eyesore that was on my bike.
A very good buy at $34.80 shipped. I just put it and the tank on to check that it fits.