77 GS750 followed me home

[Govee]

Spent a few hours today getting the garage ready for the winter. Here is a few pics of the lift table and wall mounted folding work bench.

[Govee]

valve adjustment/clearances, check my math please

I figured out how to do the valve adjustment and the below link is a pdf listing my clearance and shims. Please take a look and see if my math is correct. My feeler gauges' thinnest blade is .038mm so i made a few guesses when the .038mm would not fit.


https://docs.google.com/file/d/0Bz6p...it?usp=sharing

Thanks,
Govee

[Govee]

The tear down begins

I started pulling the bike apart for this winters rebuild. 3 hours of my afternoon and the only things left are the engine, wiring harness, and rear brake and swing arm assembly. Tomorrow its off to the salvage yard to see what I can find and get all the parts in bins so I can have my work space back. Here are few pictures of the parts explosion and one with the tank back on with the tail section moved forward. It is going to end up somewhere close to that spot.

[GSEScraze]

look twins


a pic of 2 1977 GS750 I picked up this summer seat is after market
Tom

[Govee]

That's funny. Twins separated by 500 miles. I was born and raised in Lancaster Ohio. I left there 30 years ago when I joined the Marine Corps. All my family is still down in the rolling hills south of Columbus. I picked up an GS850 to get some parts like cylinders, pistons, and a number of other odds and ends.

Go Browns! Not much love for a die hard Browns fan down here.

[Govee]

Got the front end and cylinders and pistons off the parts bike I have been stripping and separating the parts I want with the parts to sale/trade and have a lot of parts to get through. all engine accessories removed.

How do I test the stator without a running bike?

Tomorrow its get the rear end removed so I can get the frame and case out of my garage and ready for a new home some where. I am liking rusted phillips screws a lot less these days!

[ryguy425425]

Its been a long 5 or so days and haven't done much work on the bike but i Have been riding to begin to see if I can find things that need attention this winter. I also spent much of this weekend helping a friend build a house for his Harley before the weather turns bad.

I rigged up a gear position indicator since the power wire broke of the circuit board on mine and for the life of me I can't solder it back. I think it must have been nickel plated vice soldered on the board. Anyway, I used some LEDs and a small project box. I am getting used to the feel of RPM vs Speed vs sound and current gear is helpful.



A couple of oil leaks I have found. What could be the cause of these?
1.


2.


3.
This one is really perplexing. Where is oil coming from to get on the starter cover?


Almost forgot. Here is my high dollar seat repair. Upcyclers should be proud.


Got some parts from ebay to put dual discs on the front.






Looking at the rear wheel and saw this large metal object on a spoke. What is it?


Here is some possible proof that some one has been inside the valve cover before. Why else would 1 screw be missing?


Lots more to figure out but the bike starts up really easy and runs well. I do believe the speedo is off by 10MPH at highway speeds and the tach is still a little bouncy..

I had the same problem with my gear position indicator. I took the cluster in to work to use the expensive soldering irons on it, and I could not get the old solder to melt at all. I ended up having some luck by tinning the wires with as much solder as they could hold coating the whole area in flux, then just globbing on the new solder over top. Probably not the best solution, but I drowned the whole thing in hot glue so it turned out pretty solid.

Your solution looks very clean though.

[Govee]

Rear mag wheel is now fitted. This a 17" wheel vice the 18" but it looks good. Front mag is still 19" so I'm not sure if I will have to play with the forks placement (meaning do I need to push the forks up through the triple tree a little to compensate)?. I ordered, recieved and mostly installed AllBalls stem conversion bearings so I could use the triple tree, forks and brakes from the 850. I still have to put the bottom bearing on the stem. the stem is in the freezer. Will do that tonight.

[Govee]

RYGuy, I decided against what we used to refer to as 'Radio Shacked". Bigger the glob better the job! I was nuking the board with heat and not getting anywhere. Frustrating to say the least.

[Govee]

I just finished replacing the valve seals using a homemade spring compressor! First time I've ever done this and it went well. Took forever as valve 1 took and hour as I was learning, then the learning curve kicked in and the last valve took 10 minutes including scrubbing the funk of the valve, valve lapping, valve seal replacement.

I did found that replacing the shims cups was harder than I thought. They just don't go back in easily. I tried tapping them in but they would just get stuck. I finally figured I could grip the edge of the shim cup with a small vice grip and rotate the cup back and forth (twisting as if it has threads) and it would fall in place. So down pressure was bad and twisting was good. No idea why, but it made all 8 drop in very easy.

Waiting for piston rings to put 850 top end and pistons on and close up the engine. I have everything I need to start carb clean/rebuild this week as well.

[thesplashfactor]

Hey, I live in SMD too and just picked up an '81 GS750L last week. I'm going to do a cafe/flattrack/brat build. have you seen this guy's 750?

http://www.tinshackrestoration.com/2012/11/18/1979-suzuki-gs-750l-before-after/

[Govee]

Hey, I live in SMD too and just picked up an '81 GS750L last week. I'm going to do a cafe/flattrack/brat build. have you seen this guy's 750?
http://www.tinshackrestoration.com/2...-before-after/

No I had not, but wow! I am sure I am not capable of doing or paying for that level of greatness!

[Brodie]

Nice job with the valves Govee, I am up to the same stage with my engine, waiting on parts but need to do the head yet.

Keep up the good work mate.

[Govee]

Thanks Brodie.

I got some parts in over the last week and finished the engine work. 850 block and pistons are fitted and cylinder head reattached. Rechecked valve shims and valve cover is back on. I also received some parts from a member here. Got a 1100 swing arm, Marzocchi shocks, and 1100 froks and triples. I have temporarily fit these and have i question in regards to the swing arm in relation to fitting between the frame rails. I have a few pictures that highlight my concern.








These last 2 pictures show my area of concern. The swing arm makes contact with the one side of the frame and is within 1/16 of an inch on the other. Any need for concern? Should I attempt to widen the frame a little. I could put a bottle jack between the rails and stretch it a little??

[silverbullet132]

^ the bottle jack method is what I was advised to do

Those parts are looking good