1985 Suzuki GS700EF

[tejasmud]

Well, the bike is a ’85 GS700EF (California Version) from what I can tell given the gas tank, and labeling inside the left frame cover. Here are a few pictures of the bike before. She is in decent shape, but in need of a major makeover. I’m thinking about switching to the red original graphics, but have not fully decided yet.

[tejasmud]

Instead of the before/after pictures on everything the thread will progress through putting the bike back together. I didn’t really take many before pictures, but if one can imagine a bike that has been kept outside for 23 years uncovered, it pretty much describes the picture.

First thing was to disassemble the bike to the bare frame then it was escorted to the carwash, and scrubbed thoroughly to clean off any oil and residue. This took a good full day to break the bike down, wash, and sort the parts into 100 projects.

The next process involved sandblasting the frame to remove the factory paint, and carefully grinding down the welds slightly that were excessive including all splatter beads. Now, the welds were not ground down completely to blend in, sacrificing the frames strength, just cleaned up in a few spots where welds extended beyond the joints along the tubes and where extreme build up was observed. Another full day in this process, and as a ‘do-it your selfer” I had sand in my britches worse than any beach I have ever been too.

Here is a picture of the frame after powder coat. Satin black and the cost was $150 USD. Dropped off at noon and picked up at 5pm. I had another quote at $250.

[tejasmud]

The 100 project list mentioned before? Not really 100 projects yet, but sure seems like it.

All the metal pieces that were originally painted black including engine brackets, battery box, torque arm, kick stand, electronics mount, tail section parts, and fork lowers were bead blasted and repainted satin black as well.

One project included the complete rebuild of the front dampeners/forks. Parts ordered for the rebuild included, Progressive springs, Leak Proof seals, upper guides and lower bushings, both sets of piston rings, valve locks and springs, fork bolts and copper gaskets, dust seals, o-rings, and spring seats.

[tejasmud]

The spring seats that go in the top of the fork tube, which are held in place with little wire ID clips were rusted into place. The method of extraction included boring a hole through the center, and turning them out in a lathe. The surface of the ID of the fork tubes just above the spring seats on each fork tube was in pretty bad shape as well, and was cleaned up during the lathe work. Instead of going back with the wire clips, which the OEM were discontinued, internal snap rings were substituted, and the specified grooves were also cut while in the lathe.

[tejasmud]

Instead of going with the anti-dives on the forks block-off plates were made. Here are a few pictures of the process. 3/8 inch aluminum plate was used for fabrication.

[tejasmud]

New wheel bearings were installed in both front and rear rims.

[tejasmud]

Now for this bike I decided it was going to be primarily a red-light to red-light bike, not much of a touring bike for the most part, and if needed I can bump up the front sprocket a few teeth easily enough. OEM sprockets on this machine were 14t front and 45t rear. In the front I have gone with a 12t acquired from Sprocket Specialists, and going with a 47t rear purchased from a local supplier, PMP Sprockets in Wylie, Texas. Kim at PMP is awesome to work with, if there is a rear sprocket for any machine that seems unobtainable. Just call her up, and if they don’t have a pattern you can send yours in, which I have done with a few bikes. Not sure if they can do off-set sprockets, but I bet they can.

Top View


Polished Hub


New Hardware

[tejasmud]

The swing arm was stripped of clear coat, and as Stock was anodized on this bike. Sort of makes a bit of work to polish it out, but 100 hours of sanding, mini sst wire brushing with a dremil tool and polishing it nice and sparkly.

[tejasmud]

The rear shock was broken down, cleaned, and the spring was bead blasted and painted red for appearance. The dampener and pre-load controls were also disassembled, cleaned, painted, and lubed.

[tejasmud]

On the handle bars decided to go with black anodized Vortex clip-ons. For the top caps on the fork tubes I made some with a couple of black anodized plugs I had in the garage. Turned them down and added an o-ring groove to keep water out of the tubes where the snap ring and upper spring seats are for the forks.

[tejasmud]

Now we have a rolling chassis. New tank and frame cover cushions. The stainless fasteners and washers were ordered through Bolt Depot. There are a couple of specialty OEM fasteners on order like the steering head center bolt and triple clamp bolts, but soon enough.

Here is where I left off Sunday morning.

[jwhelan65]

Awesome job..that rear shock is trick! I would like to do that to mine in yellow, do you have some pics of the break down...luvin this, someone doin the same project...I'll be watching this one daily! BRAVO !

[yaddy]

Very nice, top quality work and attention to detail is first rate. I will be a regular viewer here, that's for sure.

Ps:
If you aint using that lighthouse on the front, can i have first dibs please? Lol

[jwhelan65]

I noticed you replaced the locking clips on the rear sprocket, I couldnt use mine due to the Vortex having recessed bolt holes. Hopefully not an issue down the road what do you think?

[salty_monk]

I would at least loctite them Joe...

Dan