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1981 GSX750E - My first bike

  • Thread starter Thread starter Krogare
  • Start date Start date
Safety measures

Safety measures

Ordered kits for front and rear calipers, a new front M C reservoir and a kit for the front master cylinder from z1 enterprises today. They didn't have a kit listed for the rear master cylinder though.. I guess I'll have to try and find that elsewhere. Front brakes are more important though. Already have SS front brake lines. Rear brake line looks like it could be the original one so I really should replace it. Ordered the 6 mm washer for the front sprocket as well, planning to do a 530 conversion this winter. I do need to replace the chain since I have noticed it kinking (is that the word?) a little, so I might as well go for the 530 to save a little bit of rotating mass :)
So progress this last week has only been preparations for what is planned to happen during this winters off season.
 


Thought I'd get this picture a bit larger for you. Nice to see your making some progress.

cg
 
Nice machine you have there, you're doing a great job with the care and feeding. :)

Something I thought I'd mention: Z1 sells aftermarket stuff on their web store, but for some things (especially wear items like gaskets, seals, and cables), it's better to get the Suzuki OEM parts instead. In particular, the caliper and master cylinder rebuild kits. The aftermarket versions of these sometimes have fitment and longevity issues.

I don't know what you have for Suzuki dealerships in your part of the world, but a number of vendors ship worldwide. Z1 will also sell OEM parts, but they don't have them on their website... you have to call or email them with the Suzuki part numbers.

Also, the carb bodies and jets really need to be soaked in a strong solvent to get perfectly clean. Barrymen's (if that's how it's spelled) is the forum favorite, but if yours are already pretty decent, you may be able to make do with the stuff in an aerosol can. (You can squirt it into a glass jar and let the jets and things soak that way.)
 
Ultraschall

Ultraschall

Some progress today :)

Lettin ye olde GriesHaber Ultrashall 120 work its magic:



Yup, its on:



All that gunk bubblin' away... the water was a pretty ugly greenish-yellow after...



More cleaning of little bits and bobs...



And after ridiculous amounts of high pressure air cleaning of all passages assembly with all new o-rings...



The ultra sound makes the outside of the carbs really nice and clean so I hope that is enough for the inside and the jets as well. Do you think I need to use one of those carb-dip solvent fluids even if I do a ultra sound cleaning?
 
eil said:
Nice machine you have there, you're doing a great job with the care and feeding. :)
Click to expand...

Thanks :)

eil said:
Something I thought I'd mention: Z1 sells aftermarket stuff on their web store, but for some things (especially wear items like gaskets, seals, and cables), it's better to get the Suzuki OEM parts instead. In particular, the caliper and master cylinder rebuild kits. The aftermarket versions of these sometimes have fitment and longevity issues.
Click to expand...

I already ordered those aftermarket kits from the Z1 web shop. It?s a long winter here though, I might change my mind and go with OEM rebuild kits instead when eventually I do get the calipers and cylinders apart, cleaned and assembled... Thanks for the tip eil..

eil said:
I don't know what you have for Suzuki dealerships in your part of the world, but a number of vendors ship worldwide. Z1 will also sell OEM parts, but they don't have them on their website... you have to call or email them with the Suzuki part numbers.
Click to expand...

There is one really good Suzuki parts store here in Sweden that I know of, former dealer, now "just" spare parts. Claims to have basically everything from the mid-late 70s and later, and what is not on their shelf they will source. I have heard only good things about them, so I may turn to them with part nos from alpha sports to get the things I might need without import duty charges etc..

The stuff I already ordered from Z1 I will pick up in Easthampton MA, going there for a little trip in November to meet some family :)
 
Lawn Monkey said:
Your living on the edge, my wife would kick shoot and kill if I put bike parts in the dish washer
,
you brave:cool:
Click to expand...

I have no one but myself to answer to, I can do what I want :) No wife or girlfriend that can object. Maybe not always a good thing, not sure I would put old carbs in the dish washer again :D:-&
 
New handle grips

New handle grips

Alright, so the season is over for this year as far as I am concerned, the bike is now in the garage since about a week ago.

I have started taking things apart... got rid of these, which I did not care for much...



and replaced them with these, still sticking with the same (-ish) colour :)



I hope I will find them more comfortable!
 
Last edited:
Upper shock mount sheared off

Upper shock mount sheared off

This was really not what I aimed for, seems I will need to replace the stud for the upper shock mount... Oh well, it is a long winter, there is time to get this done right :)

 
Preparations for valve adjustment

Preparations for valve adjustment

Got the valve cover off with the gasket intact. Replace or re-use and hope for the best?



Couldnt find my feeler gauge so this is where I made a halt for now.

Cheers! // Fredrik
 
If the cam cover gasket is in good condition there's no need to replace it. If you finger wipe some grease on it you might get away with reusing it a good few times and if you do ever tear it then it will be easier to remove instead of welding itself to the aluminium.
 
Hmmm..

Hmmm..

Krogare said:
Got the valve cover off with the gasket intact. Replace or re-use and hope for the best?



Couldnt find my feeler gauge so this is where I made a halt for now.

Cheers! // Fredrik
Click to expand...

I bought one from suzukiboulevard so I'm replacing mine.

Lookin' good with your project!

Ed
 
Major setback

Major setback

So, what youre looking at here is a sprocket loosely fitted on its shaft, outside it is a stripped nut which was welded in place :eek: The welds do keep it in place somewhat I suppose and then its also held in place by two M5 bolts...

:mad:I'd say that this is not an ok fix and ... Well... always take a used bike apart to see what youve got before using it on the open road?



Is there any solution to this other than to split the cases and replace the sprocket shaft? (Cause thats what I have to do to get to it I suppose?)
 
Krogare said:
So, what youre looking at here is a sprocket loosely fitted on its shaft, outside it is a stripped nut which was welded in place :eek: The welds do keep it in place somewhat I suppose and then its also held in place by two M5 bolts...

:mad:I'd say that this is not an ok fix and ... Well... always take a used bike apart to see what youve got before using it on the open road?



Is there any solution to this other than to split the cases and replace the sprocket shaft? (Cause thats what I have to do to get to it I suppose?)
Click to expand...

An idea, carefully filing through the weld, remove the bolts and see if it will come off. Then it's a case of getting a die on it to cut a new thread.

To be honest with that type of bodge I would be splitting the engine for a full service rebuild anyway.
 
Picked up a box in the US :)

Picked up a box in the US :)

Some parts that will be used/attached/fitted during this winter :)

 
Krogare said:
Its not just the stripped nut and the bolts. Its not supposed to be all wiggly like this is it?

http://www.youtube.com/watch?v=NqYaET6Rm5s&feature=youtu.be
Click to expand...

That is officially bad.

The good news is that it looks like you don't have to break those welds because it's already been done for you. The bad news is that I don't think your main shaft is any good anymore. Split the case and fix it right, I'm sure that someone around here has the part you need to make the thing go again.
 
That does suck alright. I had a 2nd gear issue on mine that I knew would require splitting the cases to fix. But you know what? It's not that tough. If you've got the service manual, a decent set of tools, a torque wrench, and a modicum of skill, you can do it. Just take your time (key) and ask if you are not sure about something. Take lots of pics along the way too. It will help. Go for it and good luck!
 
Now I'm in for this one cause it just got intrestin.. I hope you document this with lots of posts and pics of Swedish girls. I'm starting to break down a CB750 engine with much trepidation.
 
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