GS750ES Rebuild research.

[AzureCuzYeah]

Hey guys I am still pretty new here. I made an account early in the summer but I was too busy driving around to talk much. I plan to attempt a rebuild of my GS750ES. The bike is currently running and sounds great but it really looks like hell. I am probably the 5th or 6th owner of this bike which brings up a bunch of questions. There are a ton of non-stock parts on this bike or just questionable parts in general. There are things I know and things I don't and I am going to divide this thread up that way. I want to keep things proper but in order to do that I will need every ones help .

Things I know:

This was originally a GS 750 ES. It has a bunch of GS750E decals on it. I am not sure if that is the decal for the E models as I have seen so many styles lately on this site. It is obvious though that this bike has been altered. I want to make sense of these changes before I start anything.

This is a random Honda master cylinder. I am not in a huge rush to replace it but the issue is that the honda system is a bit different. When I put on the front break the break light doesn't go on. Not the biggest issue on the planet but I would like the light to go on for both breaks.

This can't be the headlight that came with this bike. It doesn't really make sense but surprisingly doesn't look half bad from far away. This light was with the bike when I bought it so the entire front cowling is gone. I don't think this is the worst but I think a different light may work better. It bothers me because of all the blank space and the fact that the turn signals are just dangling there. There is nothing for them to screw into.

The fairings I have right now are holding on by a thread. All the original connectors are broken off. There is some real redneck engineering going on right now with some strategically placed screws going into the rubber of the air cleaner. The original green shows up well on the back, so does the broken connections, I am not sure if these can be salvaged or how. Hot glue gun?

 

[AzureCuzYeah]

I have no idea if this exhaust was original. My guess is no. It has some interesting welding on it for an attachment to somewhere. Where exactly...? So I don't know what it attaches to, if anything.

The speedometer console is pretty filthy. It has several cracks on the outside, which probably led to a lot of dirt on the inside. I want to avoid buying a new one, so I figure I need to take it off and do some plastic welding with hot glue, sand, then paint. The inside is filthy though. I am worried about messing something up while attempting to clean this. I probably shouldn't be too worried though because the speedometer jumps around and the RPMs never seem to go above 1000 revolutions. Also the oil temp gauge is broken off part ways. In any case I want to get all the lights working so I am not blind at night and clean up all that dirt.

Lastly, and least important. I don't believe these mirrors are for this bike. Most I have seen are rectangles. But likes I said, not that important right now.

I will probably ask for more help later identifying stuff. In any case if you see something out of whack let me know so I can handle it appropriately. I want this bike to look more stock than bootleg (although I think I may settle for a bunch of both!).

 

[SVSooke]

OK yeah you got a few issues there alright.
First the front master cylinder.

This is what is stock for the ES.

The one you have is a earlier style one,like the one off my 78 1000.Or it could be Honda to,if the threads are 10x1.00 it's Suzuki.Threads 10x1.25 it's Honda.
Headlight is a 6(?) inch off a cruiser or smaller bike.The 84E came with a 8 inch 'train light',looks way better IMO.They can be $$ but even a 7 inch would look better.
I'd figure out a hanger bracket for that pipe.My Supertrapp attaches to the second hole in the passenger peg hanger.Might want to fab something to that.

 

[AzureCuzYeah]

I guess this will help me make a new wanted thread: Master cylinder, preferably 8 inch light, possibly the turn signals from the 84E to make the bike look right.

As for the hanger bracket that seems tricky. The clearance is like a whole foot from the frame. I need to google for some inspiration there.

 

[SVSooke]

US$ 17.95
Fits: GS750E (84-86)


Turn Signal Lamp

#11-2116 | Suzuki GS750E (1984-1986)
Turn Signal Lamp Short Stem
Parts n' more http://www.partsnmore.com/ has these repro's.Originals are all pretty far gone unless the bike was very well kept.Thinking of getting a set for mine.Hanger will be a problem,no place on the frame to put it to short of welding one on.Look up plastic welding on YouTube,it sounds harder than it is.Could be the ticket fo your insturment pod.

 

[AzureCuzYeah]

Perfect. Those will look much better. I can't stand the loose dangling turn signal look. The hanger will probably go on hold till I reassemble it anyway. I actually mentioned the plastic welding next to the pictures. I really look forward to doing this. I think that once I patch it all up I may be able to see how fast I am actually going (Speedometer jumps all over but around the actual kpm).

Tomorrow I am going to see a guy I met on craigslist. Apparently I can get a mirror finish on all my metals using a Washing machine motor, arbor and a cascade of sandpaper grits. I will take pictures tomorrow.

 

[SVSooke]

The plastic welding I do is with a soldering iron not a glue gun.If it is ABS the acetone slurry method is even better than plastic welding.I'm just not sure what that pod is made of.

 

[AzureCuzYeah]

Yeah I saw some videos. I probably can do both methods. I need to do the glue gun because in some areas plastic is legitimately gone. I need to fill in the gaps. I can probably solder the rest.

 

[SVSooke]

If it was mine I'd test it.Take a small silver and if i dissolves in acetone you a golden.Even better than plastic welding on ABS IMO.Can even use it to fill in missing bits.A bunch of info here http://www.thegsresources.com/_forum/showthread.php?t=199174 .

 

[AzureCuzYeah]

I wonder If I can get someone to make a mold of their faring pins? Mine are broken off on all sides on both.

 

[AzureCuzYeah]

Ok not the most eventful eventful day but it sure sucked up a lot more time than I expected. I am waiting for permission to clear a spot in the garage to get down to the real dirty work. For now I decided to tinker and get some of the small stuff out of the way.

I took my old bike seat and took off all the leather. The foam looks pretty gross but I believe it is still usable. Under the seat a few of the rubber bits are missing but I am not too concerned.

I took the rear brake light's red plastic off along with the back panel of the speedometer. What originally started as a "lets see what is here" turned into "I drove this for 4 months?" Nearly all the screws are different sizes and threads. I am doubting that they are remotely close to the right size. The speedometers panel is broken in several areas as was addressed earlier but also has 3 of the 4 connectors are broken off item 7. I attempted to remove the speedometer but After removing the speedometer cable and the connector that goes to items 8, 12-16, I noticed another cable with no way of detaching it so I am going to wait before I start cutting wires. After several more screws and bolts of wrong sizes, I decided to quit, to research the correct sizes.

 

[GateKeeper]

Actually you will need the rubber bits, they hold the seat at the right height off of the frame and in place as well, if one is missing the seat will cant as you sit on it.

the foam does look a bit on the grungy side, but still useable, if you get it reupholstered at a shop, they can as they did with mine put a thin layer of new foam, this will take out any imperfections and so on when the new skin is put on