Rookie Rebuild. 1980 GS750

[cowboyup3371]

Don't even need to do that. You can get an oversized plug at the car parts house or use a helicoil (I did). Do a search on here as this has been discussed frequently.

[jacobdub]

Thanks a lot for the help! I'll definitely dig through the forums more, too. I had a long weekend, so I'm really glad I got so much done. Now comes the fun stuff!

[Flyboy]

Wow, you sure have been busy, yes, getting the motor out by yourself is a pain, but there are ingenious ways to do it, me, I just straddle the frame, grab it and man handle it out....probably one of the reasons that my back is so fooked.
Getting it back in without scratching your shiny new painted frame is the fun part.
First thing that helps a bit is removing the valve cover to give more clearence, and the most popular way of getting it back in, is to lay the motor on its side and drop the bare frame over the motor.
Guys also use two planks across the lower cradle tubes and slide it in.
Jeeez, that sprocket cover did take a beating, wonder what happened there, maybe a chain come off???

[Motocrossx23]

Lol, check out my build thread, we pretty much started off the same way!

[jacobdub]

Yeah getting the engine out was actually a pretty funny spectacle I imagine. I'm a small fella', so I definitely tried laying it down (gently!) first, but like I said I didn't take all the mounts off I should have for whatever reason. So I stood it up again and took all the previously just loosened fasteners out. Then I went to lay it down again and the motor literally almost fell out! Haha then I got my buddy and we just lifted it out. We tried pulling the motor of his Yamaha out, too, but the bolt holding the oil filter on is stripped and without getting that off he's screwed. Nothing ever quite as it's planned, huh?

[Motocrossx23]

Haha, kinda like my center stand bolt...that thing was a pain in the butt!

[Hoosier Daddy]

The pipes were already painted, so I just hit them with a wire brush.

Im not sure what direction I want to go yet. Definitely a good clean and paint. Some changes here and there, maybe towards a cafe or brat style. Ive read Hoosiers thread like a hundred times! Ideas?

I am honored! Here i was excited to find your thread with another 80 "L" getting some lovin!
+1 on the oversized drain plug from the auto-parts store, easy to find, mine was only in by two threads, all the rest were stripped by the PO (previous owner). wound up going with a 2 over to get a good bite and slowly installed it, backing off a couple times using it like a tap.
And also on laying the engine on it's side and lowering the frame on it when re-installing, much more controlled.
You made a lot of progress, keep it up... I'm eager for more,
SUBSCRIBED!

[ScrumDown]

Lots done. Keep it up ROOKIE!

(subscribed)

[240punk]

There are literally 100 pans on ebay.
I dont agree with the "tap it with a bigger bolt" advice. At all.
Sure, it probably works fine. Sure, sounds easy. Sure, it's really cheap.
Or you could just do it right.
PLUS you can polish your new pan! Haha

[jacobdub]

Haha thanks scrum. Yeah punk, thanks for taking a look! Either way doesnt sound so bad to me. I'll definitely check eBay, there's tons of good stuff! Ha not sure about trying to keep that pan polished, tho!

[Cdnpt1]

Since the pan is off anyway, might as well do the oil pressure mod on the relief valve. Give me a sec here and I will add the link to it.

[Cdnpt1]

Here is the info: by the oil pump there should be a screw in valve, Part 23 in this fiche

http://www.boulevardsuzuki.com/fiche_section_detail.asp?section=94769&category=Motorcycles&make=SUZUKI&year=1980&fveh=2135

The conversation below is about what to do to increase pressure on the spring in the valve so it doesn't open as soon, keeping oil pressure up in the system. This is to minimize the problem these motors had with wearing out exhaust cams prematurely.


Hey there, i found this post in another thread. So do you replace the original little cup that is up against the circlip with two 6mm washers, or add them to the original? Can you put the washers between the original washer and the circlip? Last question, do they have to be wave washers or can they be plain ole flat washers?[/QUOTE]

Add additional washers to the stack...I'd imagine the first guy to try it just used what he had to hand and when it worked the spring washers became what to use. I estimate the 2 spring washers are around 3mm thick in total. Whatever you use as a spacer should have a hole in the center for free oil drainage.
Good luck
Greg

[jacobdub]

Thats awesome! Thanks for the tip. While not the easiest, I definitely think I'll look into swapping the pan. This site is awesome! Thanks everyone!

No new pics tonight. Started shiftwork up again. Tonights work consisted of a couple hours and a couple beers working out some plans. I think I've figured out how I want to clean up the battery area. I've got a couple things to research and parts to investigate, but I think it's going to be exactly what I want and will really tidy it up so I dont have to source new side covers! I'll sketch it out and post when Im sure!

[jacobdub]

Hibernation!

Seriously, I don't know what happened to winter. It was in the 80's today, and guess how mad I am that I've gotten so little done on the bike? VERY!

Quick update, though, if anyone's still following my lazy a$$ rebuild haha.

I did some cutting/grinding on the frame to delete the side covers, rear pegs and a couple other little things, and it's off to an AWESOME local shop for blast/powder. http://www.taylorcycleservice.com if anyone's in upstate NY. Just a couple guys working 'round the clock fixin' bikes. Awesome.
Most of the other smaller parts are clean and ready to go back on when the frame's ready.
I've got a mock up of the new battery/electronics box (made out of a Boston Lager 12 pack haha) and the materials to make it. I really wish I had my own welder, but I don't mind sharing another 12 pack with somebody for some quick tacks, either!
There's more, too, but I don't want to write it all out when I can post pics soon!

[jacobdub]

I am curious, and please understand I've tried searching for a good long time, but are there any good, detailed threads about simplified rewires for this bike? I'm interested in deleting what I can...