'78 gs750ec

[cowboyup3371]

Do you use any seal puller like what you would find at OReilly's or Autozone? Or something different?

[allojohn]

Do you use any seal puller like what you would find at OReilly's or Autozone? Or something different?

Lisle oil seal puller - Sears $10.99

[allojohn]

Finally got around to fixing the broken bolt in the head. As per instructions from Nessism & mike-s I heated the bolt with a blow torch and blasted it with Freeze Out (couldn't get hold of Freeze & Release).

I used a "QuikCenter" collar even though the cooling fins prevented it being centered perfectly over the broken bolt. I used a small drill first and progressively used larger drills working to get it centered on the bolt. I had hoped using LH drill bits might cause the bolt to unscrew but that didn't happen.





















All in all I'm chuffed to bits, this could have gone badly wrong but thanks to great advice (Nessism / mike-s) it's fixed.

[allojohn]

Calipers

Today I dismantled the calipers. I used the forum approved method (compressed air) and boy did it work well! I leaned over the rear caliper with the air hose to force air in and about half a second later the piston flew by my ear!

There was once brake fluid in here, no sign of it now.





Looks like both the front caliper pistons need replacing.

[allojohn]

July update. Painted and rebuilt the front & rear calipers, rebuilt front & rear master cylinders. Polished the forks and inserted the new seals. Polished the engine casings. Replaced clutch springs.



Put the inlet boots back on with new o-rings.



Drilled out the swing-arm mount to 16mm, to take the '82 GS1100E aluminum arm.



Dropped the oil pan for a look, just a thin layer of grime.



Stripped the tank.





So I'm ready to take the frame & tank to the powder coat dudes this week.

I was quite surprised how much light rust I found under what looked to me to be good paint, in four five random locations.

This week I'm working on the loom replacing all the bullet connections with insulated quick connects.

[jwhelan65]

Nice work so far ..looking forward to seeing it completed.

[allojohn]

Nice work so far ..looking forward to seeing it completed.

Thanks man, I'm a slow worker and I'm getting there but have a long way to go - loving every minute of it!

[allojohn]

It came off in my hands, honest.....

Can I glue it back in there? What sort of glue?



On another note, I dropped off the frame and tank with the powder coat dudes today. Dumped a ton of cash at Z1 for a pile of goodies. The build begins in 3 weeks.

[ChicagoBob]

I'm pretty sure it's just a press fit. I had the same issue, and gravity has held it in place since then (yes, I checked).

[allojohn]

I'm pretty sure it's just a press fit. I had the same issue, and gravity has held it in place since then (yes, I checked).

Thanks Bob, I think I might use a blob of silicone to make sure.

[Flyboy]

There is some nice work going on there, keep it up, I am following with interest.
Nice step by step picture story on the broken bolt removal, should come in handy for others with the same problem.

[allojohn]

Much appreciated Flyboy.

[allojohn]

Got the frame back from the powder coat guys - fabulous job, much impressed. I used foam pipe insulation to protect the paintwork. It worked very well and tore off easy once the lump was back in the frame.




I stole more tips here and used 3/8" bar to lift the engine into place.




With help from her indoors.




Home at last!




And now the fun begins......

[allojohn]

Replaced the steering head races with tapered bearings from Pyramid - went in without much trouble.



With a little modification the 1100E swinger also went on along with a new set of Progressive 12-1204's.



Tank came back from powder coat.









Now all I have to do is remember where all the wiring went, DOH!

[drivera84]

hi alloJohn,

Just read through all your build...nice work! Its coming out nicely

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