GS750 1978 Cafe 'Project Doris'

[Dec79]

Some progress last week

1) Barrels and head back from cleaners
2) Wiseco Pistons assembled and fed into barrels (note the technique, any one else done it this way?)
3) Valves lapped in, head fully assembled (one cracked valve replaced)
4) Valve clearance set
5) One plug thread attended to, ok now thankfully

Next jobs include setting the timing and rebuilding the carbs.... enjoy

Also, does anyone have any experience of the 844cc upgrade on this engine, be interesting to know what to expect plus any tuning tips. Thanks.

 

[DannyMotor]

Classy!!! This thing is gonna be a sweet one. Great work!

 

[Dec79]

A few updates from this weekend:

1) Re-tapped dodgy sump plug
2) Set timing and valve clearances
3) Installed Dyna 2000 crank pick up
4) Installed a few bits around the engine
5) Built carbs

I have a couple of questions regarding the carb set up. I'll be running pod filters and a Vance and Hines full system. I've made the following tweaks to the carbs, I'd appreciate if someone could tell me whether I'm on the right lines:

* 120 main jets
* Raised needle one notch to richen mixture
* Mixture screws 1 and 3/4 turns out (this is the manufacturers recommendation from the manual?)


Bearing in mind I'm running 844cc.... does this sound about right :?:

Thanks in advance.


A few pics

 

[wally]

That engine looks amazing! Great detail! Wow!

 

[7981GS]

Interesting to see that you made this work.

I tried it that way 22 or so years ago and gave up.
It was incredibly difficult to get the pins installed. :-k

Any pointers?
Did you make wooden dowels to support the cylinder?
Suspend the cylinder some how?


Eric

 

[Dec79]

Interesting to see that you made this work.

I tried it that way 22 or so years ago and gave up.
It was incredibly difficult to get the pins installed. :-k

Any pointers?
Did you make wooden dowels to support the cylinder?
Suspend the cylinder some how?


Eric

Hi Eric,

Yes, a couple of cable ties pulled tightly on 2 of the head bolts, you need to lower the barrels to just the right height to insert the pins in pistons 2 and 3. Lowering the barrels a bit more allows fitment of pistons 1 and 4. You need to have the pistons in the cylinders in preparation and be careful not to tap them out too far / past the rings!!

IMO it's much easier than trying to clamp the rings through the head studs

Dec

 

[Dec79]

Hi, a few updates.

Got my frame and a few other bits back from the painters. The Swing Arm and the Tank are not pictured. Many coats of lovely 2-pack gloss black give a lovely shine. Really looking forward to the assembly now.....

Dec

 

[Guest]

Nothing like a nice shiny frame to get the excitement level up (except maybe firing that baby up for the first time!). Looking good!

 

[7981GS]

The start of a Masterpiece.

Eric

 

[JimmyR]

If you are running pods and a V+H you might want to look at some RS carbs. They are specifically designed to be used in that application. They're not too expensive really and are very adjustable. Pretty sure you could get some to fit your bike.

BTW beautiful work so far, and I think your Dad's right. These bikes seem to last forever.

 

[ashdricky]

Very nice work! I cant wait to see the finished project.

 

[bottobot]

This is so inspiring. I'm working on the same bike as you right now but not going nearly as far with it. Looking forward to seeing your progress and finished product

 

[Dec79]

Mini update this weekend...

1) Finished carb rebuild, noting I had mounted them incorrectly last time
2) Refurbed reg/rect, starter motor solenoid, petcock, and ignition switch
3) Fitted new Oil Seal to kick starter engine casing
4) Replace 2 shims and finalised valve clearance
5) Blanked off gear indicator pick up, not going to be using this

Next job is to fit engine into frame, may attack this next weekend... getting excited now :lol:

 

[Dec79]

Anyone got any good ideas for a brake upgrade???

I've heard of using Ninja callipers etc, really want to go big disks on the front (300mm?) and twin pots

 

[DrunkenChekhov]

Front end swap?

 

[Dec79]

Front end swap?

Good idea mate! Any ideas what works well?

Was thinking of using as much GS as possible for now, maybe some redesign in the future when I get bored

 

[allojohn]

It's no biggy but if you ever have the need to drain the carbs while still attached to the engine you need to switch the bowls on 2 & 3. The drain screws are facing the wrong way.

 

[Dec79]

It's no biggy but if you ever have the need to drain the carbs while still attached to the engine you need to switch the bowls on 2 & 3. The drain screws are facing the wrong way.

Cheers mate, that has since been corrected

Rgds,
Dec

 

[bottobot]

Got some questions for you if you don't mind. Like how did you get your valve head so clean, inside and out? Did you sandblast it? It looks impeccable. Would you mind expanding on how you went about cleaning the engine block? Like which cleaners and procedures did you use? I have an incredible dirty and ****ty looking engine which I am trying to clean up at the moment.

 

[Dec79]

Got some questions for you if you don't mind. Like how did you get your valve head so clean, inside and out? Did you sandblast it? It looks impeccable. Would you mind expanding on how you went about cleaning the engine block? Like which cleaners and procedures did you use? I have an incredible dirty and ****ty looking engine which I am trying to clean up at the moment.

Hi mate, check out http://www.icmhome.org.uk/

I went for vapour blasting I think, head, barrels and carb bodies cost about ?200, worth every penny in my opinion!!