GS750: White Orphan Baby build

[DannyMotor]

If by chain cover you mean the cam cover, try these guys: http://www.ebay.com/itm/230731903712...#ht_624wt_1165

As for the clutch cover and stator cover, etc. call Z1 they sell kits.

Eric

Nah, chain cover... the part I painted wrinkle black in the above pics. There's to stubby bolts that go inside the clutch mechanism, and then 3 really long ones... two on the bottom and one that goes between the chain.

The links you guys all provided in the other post should include them though... I hope. Haha.

I've checked ACE and Aubuchaun Hardware... they have a limited selection last time I went in.

[7981GS]

The Z1 kit includes those impossible to find longer bolts.

Eric

[DannyMotor]

Nother' box o-goodies






Couldn't resist slapping on the motor emblems.

Got tach cable, gaskets for the cam chain adjuster, cam cover, cam cover breather, new tach drive rubber sleeve, spark plugs, new hose clamps for the carbs, new wire ties for the handlebars and a few little things... fork seals... rubber mounts for the side-covers... good stuff.

[DannyMotor]

I can feel the end closing in for the chassis...

Got the swingarm taken care of. Had some extra "aluminum" color paint so I threw it on the swingarm and it looks pretty good! I just have to do some sanding and what-not to take care of some of the unsightly ripples from poor prep.. (yay me).

Then, I attacked the exhaust. Took FOREVER to prep the damn thing. It was HORRIBLY rusty, so it took a couple different 3M drill pads... a few hours... a couple of days... a few more hours... and then I tried to separate the downtubes from the rest of the can... Nope. Not gonna happen.

So then I tried to take out the baffle... took another hour, a screwdriver (RIP Stanley) and a chisel (RIP Chester).... and I got it out.

No picture of it... but it's kinda stupid. It's just 2 tubes, off-set, and welded together. No batting, no holes... nothing. I may want to re-engineer this so it's not insanely loud...

Then, FINALLY... I got to paint the damn thing. 4 coats of VHT Flame-Proof flat-black, and then took a heat gun, crammed it up each one of the inlet pipes and let it sit there until the pipes started to smoke. Nice and cured.

[akckhim]

Flat black headers are sweet. You're making good progress

[DannyMotor]

Thanks! A little more fitting, greasing and turning a wrench and ill be able to crank it over.... i hope.

[DannyMotor]

So last night i did my last little bits of motor work. checked the valves... all within spec but most on the tight end near .0012in... so thats ok for now. then i gapped the points and set the static timing. gapped the points on the high end at .016 put a little 2 stroke oil on the rub pad and used some 800 grit and a piece of thin card stock to file the points a bit.

seems good overall. reset the bench balance and all screw turns per Basscliffs tutorial. so were in a good place so far. working on removing the old valve cover gasket and going to repaint the cover and swingarm tomorrow.


i also got my barrery box and electrics started.

Left to do before starting:
Finish electrical
New case bolts
oil
finish airbox refresh
tubes, gaskets, and clamps
rework coil mounts.. stupid emgo coils are shorter than stock.

Sooo close.

[DannyMotor]

Holy crap.

Ok...

1. Got all the wiring sorted. Finally.
2. New gaskets installed.
3. Re-painted the swingarm, airbox, springs, valve cover, rear brake, and got started on the wheels.
4. Sorted a bunch of bolts... have a bunch of the rusty junk in coke.

2 awesome things happened.

The bike came with a ton of spare parts, an air-box being one of them. After poking around trying to fix the one on the bike (the top breather vent nozzle was busted off) I took a look at the old one. Opened it up and low-and-behold... brand new, un-oiled KnN filter. Sweet.

Second thing... THE BIKE TURNS OVER AND HAS SPARK!!!

I jerry-rigged a few things, made a piggy-back ground (which is permanent) from the regulator, to the rectifier, to the solenoid, to the battery, so grounding shouldn't be an issue (still plan on getting a Shindengen RR at somepoint).

But it's an awesome starting point.


Question... when I crank the bike over (I don't have any of the hoses connected to the carbs) but carb number 3 blows air out of the vacuum hole. None of the other carbs do it, and when I put my finger over the hole it doesn't really do much... just stops the blowing.

I don't get it... can someone explain?

Pics and vids tomorrow.

[verde]

Nice work!

Question... when I crank the bike over (I don't have any of the hoses connected to the carbs) but carb number 3 blows air out of the vacuum hole. None of the other carbs do it, and when I put my finger over the hole it doesn't really do much... just stops the blowing.

The #3 carb provides vacuum to the petcock to let fuel flow. I cap mine and run a manual petcock(one less feature that can fail), but some here swear by the vacuum petcock(one less thing to remember to turn on/off). The #2 and #4 carb nipples are just vents for the float bowls(there should be tiny pieces of hose that connect 1 to 2 and 3 to 4 to let them vent through the same tubes).

[DannyMotor]

Welp that solves that mystery! Thanks! And the tiny tubes are the ones above the fuel tubes. that explains everything.

[DannyMotor]

Currently de-greasing then stripping these...




Got the electrics sorted, with the exception of the oil pressure and gear selector switch...





It only shows one... and then goes into some weird version of alphabet and numeric mumbo-jumbo for each gear.



Airbox, filter, and boots installed... just have to bolt everything down... this is more of a mock-up test fit.



One shock complete.... painted the coil, ditched the chrome cover, and polished up the body... came out alright (crappy picture does it justice).

The swingarm is also done, I just need the 2 washers that sit behind the grease seals. Might be able to source these at the hardware store.



Where she stands right now.

Using little bits of 'gold' here and there... base of the triple trees, front discs, engine mounts, possibly the rear sprocket... but I'm planning on using gold in the paint scheme...

I've now ditched the "metallic blue" idea and have adopted the notion of keeping everything a metal color... Either going with another shade of silver or gray (darker than the motor, but lighter than the frame) or just a straight-up brushed aluminum silver... who cares if it matches the motor.. it'll be the finish and shine that separates it.

Laid out the plans with a pen on my break today... Disregard the "metallic blue"... but it will definitely have the checkers down the center, surrounded by gold stripes, and then a black pin-stripe around the gold. Not sure on the side covers... they're too small for numbers... so I might adopt some tie-in with the airbox covers. We'll see.

[7981GS]

E-mail sent...

Eric

[DannyMotor]

I can't remember where I saw this... But I'm sure I've seen this on more than one bike and loved the look. Came out pretty good with the flat-black exhaust.

[DannyMotor]

THE BIKE FREAKIN' RUNS A MINT!

Fired right up after filling the bowls... which, mind you, caused a huge leak when I forgot to screw back in the bowl nut and well, there goes the nice clear-coat on my clutch cover... (rats). And I had just filled the damn thing with oil. Now I'm going to have to salvage it on the bike. OH well!

IT RUNS!!!!

Sounds pretty good, had it on PRI for a minute or two, then on RES and it calmed down a bit, no popping, but it doesn't like to be blipped right now, probably the rings need freeing up a bit and the fact that there's no airbox on it..

But I am friggen psyched. Checked the electrical while running and it seems the mount screw (ground) on the rectifier (the one on the side of the battery box) was getting warm... so I may have to doublecheck the ground... but other than that... the thing's a freakin' beast.

Now I'm in love... and now I can start fine-tuning the theme, paint, and start covering up some of the nicks and dings I made during mock-up. I'm still waiting on a few things to make it 100% done chassis wise... but the good news is...

NOW I CAN PAINT THE TINS!!!!

Video uploading... probably an hour from now.

[DannyMotor]

http://www.youtube.com/watch?v=7htOWp7K_gU&hd=1