'77 GS750, "Hahn" Stuck engine.

[SqDancerLynn1]

My first engine rebuild required a BFH A 63 Rambler with a blown head gasket. Used a 5 lb sledge to get the pistons out and a big course file to remove probably 1/8" to fix the aluminum block gasket surface.

[Flyboy]

This is going to be a goodie, I am in for the ride.
Pity I only saw this now, you could have saved yourself a heap of aggrivation with that stuck piston,
For future reference, remember, the best penetrating fluid known to man is 50/50 ATF and acetone, would have had that piston out in a jiffy.
No mind though, looking at the state of what you had to start with, I would have pulled the motor and tore it down regardless, and I am sure there will be plenty bolts you will need that mixture for.
Looking forward to the updates.

[Brodie]

Thanks Flyboy, I had the ATF/Acetone mix in for quite a while, the problem was that is would not penetrate as it was not just rust holding the piston still. The heat did the trick and the reason I used DOT3 after was so it would not light up.

Yeah the plan was to dive in and pull it all apart. Would have happened even if the engine was turning. I plan on keeping this bike for many years. No point pulling it apart once I get it looking good.

I know a lot of you on here are purists so a lot of people won't like what I plan for this bike, just a bit of Cafe will happen, old style thinking though, no point making the bike look "cool" if it is going to be a pain to ride.

I would love to stick a 450 tank or an 1100 tank on. The current tank is all beat up and in a lot of places there is just layer upon layer of bondo. See how my pocket feels after getting the engine going lol.

[pete]

Hey Brodie, glad to see you getting your thread going!

Good effort getting the piston free!

The 450 tank will be tiny for the 750 I reckon, probably won't get too many km's out of a tank of fuel I reckon... might want something a little bigger.

[Eli69]

Pickles, the drummer, doodily doo. (Ding-dong, doodily, doodily, doo.)

i hope this one comes together for ya. i also have a 750 that's froze up. i really want to get it going someday 'cuz i think the kick starter is so cool.

[Brodie]

Thanks Pete, Yeah I am thinking the 1100 would be the better choice, but the hold up for the frame at the moment is that I am not sure how far to cut it because I need to know what tank I will use so I know how far back the seat will sit.


The kick start is going to be a big help I recon. I got over it after 15 years of only kicking but after riding my SR250 around it makes me want to put a kicker on it.

Hope you get your 750 sorted soon Eli.

[Brodie]

Not much to update really, I have been painting the cases and ran out half way, had to order more.

I am waiting on a straight shift shaft at the moment and after that I can get the bottom end put back together, I will be ordering piston rings tomorrow and I should be able to get the engine back together soon enough.

[pete]

Good stuff Brodie, getting the engine back together is always a good milestone!

[Brodie]

Have not update this thread for a while. Progress is slow. Anyway here are a few pictures that should show where I am at now.


Engine painted. Still needs to be rebored to suit the 1mm OS pistons I bought.


Front Rim after a sand blast and powder coat.


Rear after the same treatment.

[pete]

Mate they look good! What paint did you use on the engine?

[Brodie]

Thanks mate. I used VHT engine enamel. Can't remember the colour name off the top of my head though.

[pete]

Cool, cheers.