Stangas GS750 - Rebuild

[stangas]

Morning all

Thought I would start a fresh thread on my build of my recently aquired GS750 instead of asking heaps of questions on the introduction section.

Just to catch you up..

I scored this bike as a swap, so been cost neutral atm. I have swapped my KX250 for this GS750 and a CRF80 for the young bloke. He is absolutely stoked!!

I have read as much info from this site as possible and have picked up quite a few tricks that I am glad I know now before I started stripping the bike.

I am breaking this build into 3 phases over 3 winters.

Phase 1: Get it licensed and ride it around till winter (complete in 4 weeks)
- Rebuild the carbies from the engine to the air box.
- Electronic Ignition and wiring tidy up.
- Instrument Cluster replacement
- New Tyres
- Inspect and flush all brakes and clutch systems ? rebuild only if necessary.
- New oils, filters throughout
- Chain and sprockets ? inspect / maintain / replace
- Valve clearances.
- Fuel Tank flush / rebuild petcock / rubbers
- Temporary seat repair

Phase 2: Rebuild the Engine when winter hits (ready for next summer)
- Top end engine rebuild. Pistons up.
- Rebuild all shocks with progressive springs up front? probably replace the rears
- Rebuild all brake callipers and master cylinders with kits.

Phase 3: Panel and Paint (ready for the following summer)
- Chassis to be sand blasted and powder coated
- Tank, fairing and side covers painted in colour scheme??
- OR
- Caf? Racer Style

 

[stangas]

LOL.. will NOT be buying any parts from australia..

everything was almost triple the price :-(

Ebay could be my best friend for this bike i think

 

[Badooka]

I respect the decision!
Do the base gasket too!!!
Good Luck!!!!!!!!!

 

[stangas]

base gasket being the one between the crank case and the cylinder block?

 

[Guest]

LOL.. will NOT be buying any parts from australia..

everything was almost triple the price :-(

Ebay could be my best friend for this bike i think

I thought I put you onto some places (in another thread) to get parts .

Cheers , Simon .

 

[stangas]

yeah my bad.. sorry simon..

I will make a big order with Alphasports today once i can figure this next question out...

My bike is 1980 as per the plate on the steering column.. but every drawing i see in Alphasports says it is a 1979 and an E.. air cleaner being the biggest give away.. But the chassis number has GS750D

I cannot find any details on what the D represents?? I am getting seriously confused.

 

[JAG]

yeah my bad.. sorry simon..

I will make a big order with Alphasports today once i can figure this next question out...

My bike is 1980 as per the plate on the steering column.. but every drawing i see in Alphasports says it is a 1979 and an E.. air cleaner being the biggest give away.. But the chassis number has GS750D

I cannot find any details on what the D represents?? I am getting seriously confused.

is there a plate giving frame and engine number on the stem,? If so do these match yours. Could be a later engine swap, or a variation for your market.

 

[stangas]

i got the frame number from the stem.. but was not aware there was an engine number also.. poor lighting

I will have a look when i get home..

I am guessing it must be an aussie thing.. there is no fuel tank sender unit either?

Cheers

 

[GateKeeper]

frame numbers and engine numbers do not match on our bikes

 

[JAG]

i got the frame number from the stem.. but was not aware there was an engine number also.. poor lighting

I will have a look when i get home..

I am guessing it must be an aussie thing.. there is no fuel tank sender unit either?

Cheers

In the UK, the GS750DB, is marked on the frame stem as GS750D. This twin disk front spoked wheels, unlike the US version. Various UK companies sell parts, most later E model parts are inter-changable.

If there is a manufacturer's plate on the stem this will give both the frame and original engine number. This iscwhat I meant by do the numbers match.

 

[stangas]

This doesnt look good.. LOL

All unbolted and floating around behind the side cover
This could be a problem!

 

[stangas]

and 4 separate coils?

Nothing like the originals i was expecting.

Theoretically this should still work?? I have not proven spark when i kick it over yet

 

[Badooka]

base gasket being the one between the crank case and the cylinder block?

Yes if it leaks after your upper rebuild you have to tear it all down just to get to it.

 

[stangas]

cheers for the heads up

 

[stangas]

All my stainless hex head bolts turned up yesterday along with the carby gaskets.. Woohoo.. Not bad.. not even 7 days from the US of A

ripping the carbs out tomorrow..

Any tips before i start??

I assume you would start at the air box and work my way back to the engine

 

[stangas]

got the carbs off and doing a full blown inspection.

Carbs look sweet... nice colour inside
All the boots were stuffed.. glad i ordered that stuff
air box is getting a full degrease, paint and sealing
inside of engine at carbs looks nice too...

I reckon this air was what put this bike off the road.. i am predicting it will run as soon as new rubbers and carb orings go in.

fuel cock filter tube is broken.. just the filter section.. got a rebuild kit coming, but not the filter section.. will this affect the fuel delivery? or just not give me a reserve?
Replace it with an external inline filter?

Rear brake calipre went right back on.. about to put fluids in it and prime it

Instrument cluster saga.... buying one of these to sit neatly behind the headlight.. i dont need a tacho.. just indicator, high beam etc. What you think?
http://www.ebay.com.au/itm/Mini-Chr...ccessories&hash=item27d7691c0a#ht_2543wt_1005

 

[stangas]

All my carb boots and orings arrived today

Got an extra day off tomorrow too..

Shed time, here i go