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1979 GS750E Rebuild

  • Thread starter Thread starter JAG
  • Start date Start date
Well I'd love to get stuck into the airbox but I'm out Doo Wopping and Burlesque, so the work will have to wait till the morrow.

Plan on the airbox. The side seals are crucial to be kept intact as is the snorkel bit as you can't buy them. As I'm sure many of you know. However if I can get them off intact, not only can I use them again, but I should be able to use them as patterns to have spares made up.

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There's a lot of gunk so I really want to get inside the box to give it a real good clean.

As for the trumpet inlets, I already have a brand new set waiting to go on.

The plan at present is preheat my oven to 70C, (after all I don't cook in it) and after removing all ancillaries heat the box and rubbers up to temp to see if they soften and come away nice. (fingers crossed)

If they do great, just a case of washing the box (now now behave), before giving it a good rub down and respray.

Side covers are actually in ok condition. No dents just flaking chrome and surface rust. I'll clean them back down to bare metal and send them for a rechrome with some other bits later. Or maybe I'll just respray them black. Who knows.....

In short the final bike is being pulled in several directions. Sort of in a mind to just get her running and on the road for minimal fuss, and then focus on the "B".
 
Don't know what kind of oven but I wouldn't. Parts of it can be a lot hotter than 70C not to mention metal bits absorbing radiant........blah blah.
Basin of water wont do that and you'll get some cleaning for free.
 
Brendan W said:
Don't know what kind of oven but I wouldn't. Parts of it can be a lot hotter than 70C not to mention metal bits absorbing radiant........blah blah.
Basin of water wont do that and you'll get some cleaning for free.
Click to expand...

Old electric oven. How about I turn it regular like a roast?

Hmmm..... OK maybe I'll try the hot water first.
 
JAG said:
Old electric oven. How about I turn it regular like a roast?

Hmmm..... OK maybe I'll try the hot water first.
Click to expand...

Good move. Its probably got a bang bang controller and the elements will be over 500 at times and the heat capacity of your pressie ...........................
 
Brendan W said:
Good move. Its probably got a bang bang controller and the elements will be over 500 at times and the heat capacity of your pressie ...........................
Click to expand...

Bang bang controller? My pressies heat capacity!!! Why Mr Brendan.... Maintain some decorum sir. I beseech thee
 
So the airbox has been stripped to component parts.

Removal of the seals was easier than anticipated. All I did was gently lift the inner edges to free them up where possible, and then ran a blunt edge around the rim gently prying and lifting as I went.


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​

As can be seen in the following set of photos the box is in excellent condition for it's age, with little to no corrosion in the common areas such as the engine breather inlet.


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The foam filtre element seal will need replacing.

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As will the filter element. Although this was always going to be the case, I found it interesting what 36 years of oil does to a piece of foam...

This just crumbled to the touch....

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....leaving nothing but coffee grains.

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I have new carb boots already, so besides a new foam seal for the filter and a new filter element, all that needs to be done is a good wash and possibly a respray

'appy daze.
 
Yep, mine did the same thing. Horrid stuff. I replaced it with a K&N filter that I got on eBay. Supposed to be good for a million miles, if you clean it semi-regularly and believe their marketing.
 
eil said:
Yep, mine did the same thing. Horrid stuff. I replaced it with a K&N filter that I got on eBay. Supposed to be good for a million miles, if you clean it semi-regularly and believe their marketing.
Click to expand...

Yeah that's the plan here to. The K&N is on order at the moment. Meawhile I found another set of end covers for the box that I'd forgotten I had. They've only a couple of dings so they're back on. Also decided a respray can wait till later. As a result the box is on and in place. Just waiting on the carbs to come back from their clean and rejuvenation service.

After that I'm just gonna replace a leaking head gasket, sort the valve timing, give the head, cam chain tensioner a little clean, new oil filter, new battery, new tyres and get her back on the road for the end of February / beginning of March.

The full rebulid will occur later in the year. Pictures will follow of the airbox in place soon.
 
That's a busy looking airbox. I was able to acquire a secondary airbox for my Parts Bike from a fellow GSer. She's on my to do list so that's why I am interested in how much of a breakdown/rebuild you will be doing. Here she is all alone in the garden shed:

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I have an engine stand from Harbor Freight (HF) which cost me <$40 and I'm very excited to see the intricate details of the motor. Not sure when I'll be doing this task as I am working as a contractor 800 miles from home.

I still haven't decided if I want to bring my Riding "T" to Florida...she needs lots of work and storage is the main concern...not only for her but my foldable trailer which I also bought from HF.

The airbox I purchased did not have all the inner parts you have on your recently purchased airbox. All I used was warm water and dish soap to wash but I never took pics.

Continue updating...I enjoy your replies.


Ed

NOTE: Here's some random pics I found with my riding "T" airbox...along with other components.

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Last edited:
GSXR7ED said:
That's a busy looking airbox. I was able to acquire a secondary airbox for my Parts Bike from a fellow GSer. She's on my to do list so that's why I am interested in how much of a breakdown/rebuild you will be doing. Here she is all alone in the garden shed:

attachment.php


I have an engine stand from Harbor Freight (HF) which cost me <$40 and I'm very excited to see the intricate details of the motor. Not sure when I'll be doing this task as I am working as a contractor 800 miles from home.

I still haven't decided if I want to bring my Riding "T" to Florida...she needs lots of work and storage is the main concern...not only for her but my foldable trailer which I also bought from HF.

The airbox I purchased did not have all the inner parts you have on your recently purchased airbox. All I used was warm water and dish soap to wash but I never took pics.

Continue updating...I enjoy your replies.


Ed
Click to expand...

Nice looking bike. I don't know much about your airbox as it looks different to mine. However if your missing the inner rubber end seals as I expect, and possibly the foam seal for the air filter unit, I was looking at how I could make these up to repair my other box.

Basically I made some blanks using a packing foam and planned to hand cut some rubber sheeting. I did a search for the necessary oil/heat resistent material for seals on interwebby thing and found you can get the stuff on eBay for about $30.

I post up some pics and links later. Hope this helps.
 
Last edited:
Jo,

I added more pics of the airbox on my reply...to include my trailer. I'll take better pics when I go home next week.


Ed
 
Last edited:
How to make replacement rubber airbox seals.

How to make replacement rubber airbox seals.

Cut a piece of packing foam to a suitable size.

Hand press this on the the edges of the airbox in order to leave indentations of where the foam needs to be scored. Mark these lines out with a permanent marker and then draw in the edges of the seal to be cut.

Cut out a rough blank as shown below.

Foam blank being marked and cut,

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Clamp this into place with the metal sidepanel as a trial fitment.

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This will highlight areas needed to be trimmed. Source material such as this from custom gasket material suppliers, use your foam blank as a guide cut out a rubber seal and score in a similar manner.


Scan through the suppliers homepages to find a suitable material (thickness, sealing, oil / heat resistance properties)

This foam gasket seal is also missing.

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Seen here in the second airbox I sourced. Again go through the custom gasket material suppliers homepages and you will find a suitable material

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Jo
 
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