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General => Restorations Diary => Topic started by: Sfbrain on April 04, 2017, 07:51:45 PM

Title: Suzuki GSXR750 1985
Post by: Sfbrain on April 04, 2017, 07:51:45 PM
As requested here is the Gixxer thread  8)

I will post a couple of posts to bring you all up to date.

I've just surprised myself to find that i bought this bike almost 7 years ago !!  :o

This is how she arrived ...

[attachimg=1]

A Japanese import (UK bikes didnt have fuel gauge), mainly original apart from paint job, nexus exhaust sytem and a few 'extras'

[attachimg=2]

First thing i did was start collecting original parts (the exhaust shield covered in small holes, is unique to the 1985 model).

[attachimg=3]

My plan is to restore her to UK spec (different loom, side stand switch, different clocks), want her to eventually look like this  8)

[attachimg=4]

Another update post after i've had my dinner  ;D

 ;)
Title: Suzuki GSXR750 1985
Post by: Motty on April 04, 2017, 08:21:31 PM
Great news another Rebuild Thread  :D  :D  :D  :D 
{settles down in comfy chair}
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on April 04, 2017, 08:27:50 PM
Update post 2  8)

I'll start with a little bit of History regarding Gixxers

1985 saw the intoduction of the GSXR series with the GSXR750F (my one), this was the only model introduced at the time.

1986 saw the introduction of the GSXR1100 with the 'G' model and an updated 750G  8)

Sounds good, but the update to the 750 in 86 involved quite a few changes.

The whole front fairing (top, middle and belly) was changed, making the 85 models fairing unique to that year (and making them very rare  :-[ )

The 86 swing arm was also about 30mm longer than the 85, again making the swing arm, brake torque arm etc unique to the 750 85 too  :-[

Thereafter, the 750 and 1100 shared almost all parts, so the 1985 750 is unique in many ways from all subsequent 'slabside' Gixxers. It is also the very first Gixxer  :)

With the fairing pannels hard to come by, i started collecting them, as the ones on the bike were 'damaged'

[attachimg=1]

Once i had a decent set, i sent them off to TC for paint .......

[attachimg=2]

[attachimg=3]

[attachimg=4]

[attachimg=5]

All this lovely paint work is currently wrapped up nice and warm in my attic  :P

I did some stripping down a couple of years ago, and got it to this ....

[attachimg=6]

Then i did several Yam restos that you have seen (well some of them), after i had finnished the 2 x 350B's i promised myself i would get back to the Gixxer.

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on April 04, 2017, 08:58:35 PM
For completeness, here are the pics i posted in 'Piston Broke'  8)

She went back on the bench

[attachimg=1]

Major issues with the aftermarket exhaust system meant i actually cut it off the engine, which also means i have to get some stud removel work done on the head when its off the engine.  :-[

With the exhaust off and a few other bits off, i only had one thing still to remove before taking the engine out of the frame ......... the front sprocket. When i mentioned this on a.n.other forum, they all fell about laughing.
Apparently these are a major issue with this engine  :-\

To keep this short, i tried to remove the sprocket retention nut with my socket set, the chain still on and the rear wheel locked in place by threading some timber through the spokes ..................... NO LUCK.

Next, with advice from a Gixxer forum, i tried a 'Windy Gun' ..........................NO LUCK

Then i heated it up with a blow lamp and again hit it with the 'Windy Gun' ............ NO LUCK

Then my mate 'Rattle; brought a 6 foot steel tube  :o  which we put on the T-Bar and 32mm socket and went for it with 6 foot of leverage  :P :P :P

This is what it did to the T-Bar

[attachimg=2]

Apparently, Suzuki used large quantities of loctite on it and torqued it up to nearly 100 Ft lbs !   :o :o :o

Fearfull of causing damage elsewhere (transmision, wheel spokes, my back !!  :-X  ), i decided to leave the sprocket on and tackle it when the gearbox is out.

So Rattle and i draged her outside and laid her down.

[attachimg=3]

15 mins later the engine was out  :P

[attachimg=4]

Today i completed the chassis strip

[attachimg=5]

Thats up to date guys

More soon

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: kawazonkey on April 04, 2017, 09:41:34 PM
Looking forward to this. One question, where on earth did you find an original exhaust? I thought they had all rusted to oblivion years ago!
Title: Re: Suzuki GSXR750 1985
Post by: mervin on April 04, 2017, 09:52:46 PM
Steve . I had a similar problem with a TDR 250 front sprocket, I ended up drilling a hole through the side of the nut (as large as possible ) then split it off with a cold chisel
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on April 05, 2017, 08:14:14 AM
Looking forward to this. One question, where on earth did you find an original exhaust? I thought they had all rusted to oblivion years ago!

Hi Kawazonkey

I found the exhaust system on ebay at the same time i bought the bike, so about 7 years ago.

If i remember correctly i paid £200 for it, there is one on ebay at the moment for £700+ (which is more than i paid for the bike) :o

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on April 05, 2017, 08:18:07 AM
Steve . I had a similar problem with a TDR 250 front sprocket, I ended up drilling a hole through the side of the nut (as large as possible ) then split it off with a cold chisel

Cheers Merv, yes i was thinking about doing this, or maybe using a 'nut splitter' on it.

Either way, i recon it will be easier to do with the output shaft out of the bike and the sprocket clamped in a vice, more room to work round it.

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: stukey on April 05, 2017, 08:33:27 AM
I have a good selection of big hammers and chisels.I also have a kango hammer ,can bring them up saturday :o :o :o
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on April 05, 2017, 02:50:12 PM
This morning i got my jet blaster out and blasted the frame/swing arm.

Obviously water only shifted the dirt and road grime but its a good start

[attachimg=1]

Over the interveining years i have been buying up bita and pieces for the bike whenever i've seen them available cheap.
This morning i decided to open up all the boxes and remind myself what i had aquired, i was very pleasantly surprised how much good stuff i have.
Loads of NOS, brake lines, cables, switches etc etc, 2 complete locksets, 3 looms, 2 chainguards, rear mudguard, air filter, cam chain etc etc etc

Here it is ......

[attachimg=2]

Then i had a think about what jobs i should prioritize reflecting time needed by external suppliers.

Start with i'm going to strip these as Phillpotts have a leadtime of 6-8 weeks on rechroming

[attachimg=3]

Going to strip the wheels down so i can get them repainted and then start on this ........

[attachimg=4]

[attachimg=5]

I will be getting the engine repainted proffesionally so need to strip it completly before sending out

More soon (ish)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on April 05, 2017, 04:50:54 PM
Couldnt resist a quick peek  :D :D :D

[attachimg=1]

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Chunk on April 05, 2017, 06:55:03 PM
I will be following this one looks very interesting! I used to have a black GSXR750M, it was a beast to say the least! :D
Title: Re: Suzuki GSXR750 1985
Post by: Jimbo66 on April 06, 2017, 12:47:36 PM
Looks like it has oil changed and good quality often  ;)
Title: Re: Suzuki GSXR750 1985
Post by: Jimbo66 on April 06, 2017, 12:53:56 PM
A hammer only sds drill is worth its weight in gold being a sparky👍
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on April 06, 2017, 06:31:08 PM
Todays update, the day started well and then disaster !!!  prepare yourselves for a shocker !!  :o

First off i stripped the forks so the stanchions can go off to Phillpotts

[attachimg=1]

Then stripped the wheels down so they too can go off to be repainted

[attachimg=2]

Off with the signal generator cover (so i can turn the engine over)

[attachimg=3]

Then on to the cylinder head

Out with the cams

[attachimg=4]

And off with her head !!

[attachimg=5]

And this is when the 'Disaster' revealed itself  :-[ :-[ :-[

Some water had got into cylinder #1  :o :o :o

[attachimg=6]

[attachimg=7]

Bugger, Bugger, Bugger  :'(

At this point i packed up and went for a beer.

Fortunatly the cylinder in question was at the bottom of the bore, so removing the barrel does not involve running the piston over the rusted area.

I'm now retiring to consider my next move  8)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on April 06, 2017, 07:30:39 PM
O dear, That could end up expensive  :'(  but these things happen, Chin up could be worse.

Well i didnt know the state of the bores, so a rebore was always possible (its on std bore now), so i guess i now have to factor in a rebore  :-[

Good job i only paid £600 for the bike  ;D
Title: Re: Suzuki GSXR750 1985
Post by: stukey on April 07, 2017, 06:34:12 AM
A nice set of wossners in there will do the trick :) :) :)
Title: Re: Suzuki GSXR750 1985
Post by: nsrnick on April 07, 2017, 09:41:35 AM
A nice set of wossners in there will do the trick :) :) :)


Itl rattle...................... :P
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on April 07, 2017, 11:41:30 AM
Just a little this morning ....

Thought i would at least let the Dog see the Rabbit

[attachimg=1]

Off with the cylinder, the right hand piston looks wet, thats because i used some WD50 to help the piston with the rusty bits  :)

Weighing up the options at the moment, there are a few .......

                See if it will clean up (unlikely without rebore)
                Aquire another set of barrels & pistons (cheapest option but unknown condition)
                Full rebore with new pistons etc etc  (Most expensive, likely cost around £600  :o )

Argentina this weekend and working next week, so i have a bit of time to mull it over  ;D

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Jimbo66 on April 07, 2017, 02:06:40 PM
That is quite newer engine compared to Rd did Suzuki use a plated bore on the early gsxrs?
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on April 18, 2017, 07:18:01 PM
Not had much time recently, what with working for a living  :o and having family here for Easter  8)

However,  off with the pistons

[attachimg=1]

off with the electronics

[attachimg=2]

then started to strip down the head

[attachimg=3]

A previous owner fitted a stainless exhaust but used the 'Honda Style' collets to fit it to the head, this was a bad move as the collet seizes onto the bolts that secure it to the head. Suzuki dont use thick collets.

Anyway, after big struggles to seperate the headers and collets from the head, i now have 5 studs to remove  >:(

[attachimg=4]

Working on Texas Motogp next week (and have other issues to fix), so it might be a week or two before i get to do much more ............

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: 5port on April 20, 2017, 05:21:20 PM
Sorry to see someone has buggered that up for you!  Enjoy your steaks and red vino in Argie! ;)

5port
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on April 28, 2017, 07:19:40 PM
An update guys  ;D

Been working ths week so not much done  ::)

Clutch cover off

[attachimg=1]

and out with the clutch

[attachimg=2]

Then out with oil pump drive and gear selector mechanism

[attachimg=3]

Thats the clutch side ready to split the cases,

Then over to the other side and remove cover from starter clutch

[attachimg=4]

I did try to remove the starter clutch but, again it was fixed on the crank taper incredibly tight.

As the crank cases can be split without removing the starter clutch i have decided to leave it attached

Afew other bits removed and the left side ia also ready to split the cases

[attachimg=5]

Next the engine came out of its stand and was turned over to remove sump

[attachimg=6]

Sump cover off

[attachimg=7]

[attachimg=8]

Removed oil pump filter housing and a few internal feed pipes, and not the bottom is now ready for the cases to be split

[attachimg=9]

Next job ........ split the cases  :)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: stukey on April 28, 2017, 07:28:27 PM
Cracking on mate :) :)
Title: Re: Suzuki GSXR750 1985
Post by: julesuk on April 29, 2017, 07:12:35 AM
Ohah.  A four stroke rebuild ! Only just found this and a Suzuki .
I so love the four strokes especially the GS models. The most robust of
Engines. Yours a bit newer .
Quickly catching up on it could you not just hone that barell ?
Or has it gone too far and needs a rebore ?
Did it run when you got it ? Is it complete ?
I'll follow enthusiastically. Be so good to be standard UK couloirs.

Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on May 03, 2017, 07:09:59 PM
A bit more has been done on the Slabby engine  :P

Acording to the manual, you lift the bottom case off the top case .........

[attachimg=1]

Jobs a goodun

[attachimg=2]

[attachimg=3]

Gearbox looks good  8)

[attachimg=4]

As does the crank  :)

[attachimg=5]

Next job is to strip the head down ......

Maybe more soon, Jerez this weeked  8)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on May 04, 2017, 06:58:27 PM
Quick update  ;D

Todayd project was the cylinder head .....

[attachimg=1]

First removed the rocker arms and assemblies

[attachimg=2]

Then 16 of these

[attachimg=3]

And thats it, a completley stripped cylinderhead

[attachimg=4]

The bike is now in just about the greatest number of pieces  ;D
and i've used nearly 100 plastic bags.

Few jobs to get sorted, including getting this sprocket off the drive shaft

[attachimg=5]

The top engine case has got two oil pipes seized in it, and the cylinder head has three exhaust bolt studs seized in it, so they have to be removed.

Then the all the cases, covers, barrels and head will be off to TSR Dave to be cleaned up  8)

Not sure what i will tackle next, maybe the carbs, or maybe the loom and electrics ??

Jerez starts tomorrow, so wont be doing much more for a week or so  :P

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on May 14, 2017, 02:09:11 PM
Not much to report this week guys  ::)

Engine cases ready to go to TSR Dave

[attachimg=1]

And sorted out stuff for Zinc/Treatment, Silver/Gold/Drab Olive

[attachimg=2]

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on May 16, 2017, 08:04:15 PM
Small update,

Remember that sprocket nut that wouldnt come off, and did this to my T-Bar ?

[attachimg=1]

Well today, my mate Rattle and i used a big vice, a drill and a sharp cold chisel on it  :D

Result ..............

[attachimg=2]

Then started to strip these bad boys .....

[attachimg=3]

Also some bad news and some good news ...........

First the bad news, spent £450 on Suzuki parts today (half of that was new rings)  :o :o :o

And the good news is, my lovely wife, who is something big in Marketing  ::) , came home with 4 complementary tickets to the Pink Floyd exhibition at the V&A  :P :P :P :P

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Motty on May 16, 2017, 09:55:39 PM


complementary tickets to the Pink Floyd exhibition at the V&A  :P :P :P :P

Sounds a very pleasant trip is being planned

Sent from my XT1032 using Tapatalk

Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on May 21, 2017, 08:02:02 PM
Not done much on the bike this week, but i can highly recommend a visit to the Pink Floyd exhibition at the V&A, it id fantastic !!   8) 8) 8)

Started to tackle these ...

[attachimg=1]

Stripping them down now so i can send some parts out for metal treatment silver/gold/olive drab  :)

[attachimg=2]

Managed to get the outer carbs off the throttle bar (the spring going off to be made gold again)

[attachimg=3]

However, i'm currently stuck with the two inner carbs on the throttle bar, on the outer side of them are a small cask block on one side and the throttle butterfly (where the cables attache) on the other  :-[

The manual says they are both attached to the throttle bar by a 'pinch bolt', but not on mine  ::)

On mine, both are attched by rawl pins

[attachimg=4]

Currently asking about it on the 'Slabby Forum', but i guess i am going to have to knock the pins out  ???

'worky' week next week, so more later

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Johncb500 on May 21, 2017, 08:43:03 PM
coming along ,

  have you tried Cruzimage for carb reuild kits ?

 they have a very good reputation and range
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on May 21, 2017, 09:43:17 PM
coming along ,

  have you tried Cruzimage for carb reuild kits ?

 they have a very good reputation and range

Not looked recently at the Cruzimage kits, last time i looked they didnt make one for the flatside GSXR.

Will look again tho  ;D

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: stukey on May 22, 2017, 11:10:46 AM
Going good steve👍👍
Title: Re: Suzuki GSXR750 1985
Post by: Phil S on May 22, 2017, 12:34:42 PM
Steve,

The pins look like a smaller version of the old ford door hinge design whereby they are split and have to be tapped out. When I had a Suzuki Robinsons foundry were really good for spares.

Keep up the good work, great thread,

Phil
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on May 29, 2017, 12:46:37 PM
Next update  ;D

Carbs completely stripped and ready to go to TSR Dave for aqua treatment.

[attachimg=1]

Ordered a few more parts for the carbs from Suzuki, just gotta order new jets.

Next job will be to tackle these  :)

[attachimg=2]

More soon ish

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Comms Guy on May 30, 2017, 12:27:41 AM
Been keeping the Chinese/ Indian delivery guys busy then ?? ;D ;D ;D
PS- Great thread again
Title: Re: Suzuki GSXR750 1985
Post by: stukey on May 30, 2017, 07:50:49 AM
comming along nicely :)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on May 31, 2017, 11:04:55 AM
Got all excited this morning when i got a text to say DHL were delivering to me today  :P

A little dissappointed at the size of the parcel

[attachimg=1]

And inside was a bag full of Genuine Suzuki parts  :)

[attachimg=2]

You dont get much these days for £450  :o :o :o

Engine cases, wheels and some stuff for paint are currently with TSR Dave.
Phillpotts called to say the stanchions would be back next week
Silver and Gold Zinc are currently out
Olive Drab and calipers will be off to NSRNick in a day or so.

Starting to come together now

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Comms Guy on June 01, 2017, 08:28:11 PM
Very nice, Steve. Attention to detail is good. A question, I need to refurb the front end of My GSX1400 and wondered who You used for genuine Suzuki parts?? ;D ;D
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on June 01, 2017, 09:11:28 PM
Very nice, Steve. Attention to detail is good. A question, I need to refurb the front end of My GSX1400 and wondered who You used for genuine Suzuki parts?? ;D ;D

Hi Comms Guy,

There is a clue on the box  ;D

I use MSP, based in Holland but you can buy in pounds or Euros, very good website, and their prices are at about 20% cheaper than Suzuki UK and CSMNL  8)

They also do offers and discounts to regular customers, i actually got an extra 10% with this lot and another order i placed this week.

Sadly they dont do much stuff for bikes pre about 1985 but i'm sure they will do parts for your GSX1400


Website here https://www.motorcyclespareparts.eu/ (https://www.motorcyclespareparts.eu/)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Comms Guy on June 02, 2017, 12:25:07 AM
Cheers :) :)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on June 09, 2017, 06:00:14 PM
Not much happening at the moment, large chunks of the bike are out with others at the moment.

Also i have 4 races in 5 weeks so gotta do my day job  :-[

However, i do like it when stuff starts to come back ......

Some shinny stuff

[attachimg=1]

And the fork stanchions should be back from Phillotts next week too

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on June 22, 2017, 04:36:59 PM
More stuff coming back  ;D

Stanchions

[attachimg=1]

Had a trip over to see Dave at TSR to collect my stuff.

Delivered some of it (wheels, bars, top yoke etc) to the painters.

And brought the engine home for me to paint

[attachimg=2]

A bit of masking to do now  ;D

 ;)
Title: Suzuki GSXR750 1985
Post by: Levy1982 on June 22, 2017, 10:39:44 PM
I can't wait to see this ????


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Title: Re: Suzuki GSXR750 1985
Post by: RD17 on June 23, 2017, 08:39:22 AM
I can't wait to see this ????


Sent from my iPhone using Tapatalk

Same! A few more parts than the 350B!
Title: Re: Suzuki GSXR750 1985
Post by: Paul Dawkins on June 23, 2017, 12:08:17 PM
Looking good Steve, let me know when your going to Dave the Tossers next, I need to go that way soon and we could meet up for breakfast.
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on June 23, 2017, 04:34:48 PM
Looking good Steve, let me know when your going to Dave the Tossers next, I need to go that way soon and we could meet up for breakfast.

OK Paul, should be in a week or so to collect my carbs  :P

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on June 23, 2017, 06:55:37 PM
Now i have the bare engine cases back i'm going to paint them myself.

These Suzuki engines were painted, from the factory in a grey colour, so i went to RS Paints for the correct colour paint and laquer (Satin).

Seeing as there are a lot of parts to paint i decided i wanted to test the RS Paints first, just in case it was rubbish  ::)

So, a 3 phase paint job, first a coat of Acid Etch primmer, followed by 2 thin coats of colour and then 2 thin coats of satin laquer. Instructions stated that each phase could be baked off at 60 degrees.

Picked a small piece for the test and had a go ...............

[attachimg=1]

Colour is very good, happy with that  8)

On with the rest of it  :)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on June 28, 2017, 06:07:01 PM
Busy time for me at the moment, assen last weeked and Sachsenring this weekend  ::)

So only a little progress.

The engine cases are all primed with Acid Etch

[attachimg=1]

[attachimg=2]

And some is getting some colour

[attachimg=3]

[attachimg=4]

And got a parcel today from NSRNick, beautiful calipers, mastercylinders and some 'Olive Drab'  :P

[attachimg=5]

Hopefully, in a couple of weeks and can really get stuck in to this project by starting the engine rebuild  :)

 ;)
Title: Suzuki GSXR750 1985
Post by: Motty on June 28, 2017, 07:07:26 PM

It's all starting to come together  8)
I don't know how you manage to rebuild your bikes so quickly and also do your day job  ^-^

Sent from my XT1032 using Tapatalk

Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on July 02, 2017, 06:11:54 PM
Quick update, there are 11 different peices of engine to paint.

So far i've now primed them all and now they have their colour on them

[attachimg=1]

Working on the day job this coming week, but should be able to also complete the final stage of painting, which is a couple of coats of SATIN Laquer   8)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: stukey on July 03, 2017, 07:42:20 AM
Comming along nicely.Soon be ready for next project steve :) :)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on July 03, 2017, 07:19:20 PM
Comming along nicely.Soon be ready for next project steve :) :)

 :D :D :D

I'm always looking out for new projects  ::)

Trouble is, i have 4 projects at the back of my shed waiting  ::) ::) ::)

and i've got my eye on another one on ebay at the moment  :P

I really must do a few of my existing ones but i just cant help myself  :D

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on July 05, 2017, 07:10:12 PM
Satin laquer on now

Bit of cleaning up to do, then i can start on the engine rebuild

[attachimg=1]

[attachimg=2]

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on July 10, 2017, 03:36:57 PM
Oooooops  ::) ::) ::)

You may have seen in another thread that i was bidding on another project  8)

Well, i won that too, its another Suzuki 4-stroke tho  ::) and quite a project to do.

This is what i bought .......

[attachimg=1]

Yep, we used to call these bike 'Ice Cream Van' back in the day  :P

When i've done with it, it should look like this

[attachimg=2]

Wont be even starting the project for quite a while, but i will start collecting parts for it  :)

Always liked them, back i the day.

750 engine rebuild starts imminantly so will put up the odd post/pics

 ;)
Title: Suzuki GSXR750 1985
Post by: Motty on July 10, 2017, 07:53:05 PM
I have always liked the look of that particularGS1000, I will look to when you get to rebuild that one

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Title: Re: Suzuki GSXR750 1985
Post by: kawazonkey on July 10, 2017, 09:25:59 PM
That takes me back! I had a white and blue one as well.
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on July 18, 2017, 12:14:49 PM
Time for a little update  :D

Been to see Dave at TSR to collect the carb bodies

[attachimg=1]

Lovely job  :)

Then visited a new painter who had the 'satin Black'
Painted in 2pack  ;D

[attachimg=2]

[attachimg=3]

Time to start the rebuild  ;D

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: stukey on July 18, 2017, 05:17:34 PM
looking good
Title: Re: Suzuki GSXR750 1985
Post by: tz750d on July 18, 2017, 06:34:31 PM

Yep, we used to call these bike 'Ice Cream Van' back in the day  :P

When i've done with it, it should look like this

(Attachment Link)



Very nice find: the blue/white livery GS1000S is called a Wes Cooley special in the US - they go for big money. A very original one just sold for over $15K.

http://www.ebay.com/itm/1980-Suzuki-Other-/232350283672?hash=item361927f798%3Ag%3A-iQAAOSwYlRZKI8x&vxp=mtr&nma=true&si=ESxnEjUdWv%252FC3zxRPHnsazMTTRE%253D&orig_cvip=true&rt=nc&_trksid=p2047675.l2557 (http://www.ebay.com/itm/1980-Suzuki-Other-/232350283672?hash=item361927f798%3Ag%3A-iQAAOSwYlRZKI8x&vxp=mtr&nma=true&si=ESxnEjUdWv%252FC3zxRPHnsazMTTRE%253D&orig_cvip=true&rt=nc&_trksid=p2047675.l2557)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on July 18, 2017, 07:36:09 PM

Yep, we used to call these bike 'Ice Cream Van' back in the day  :P

When i've done with it, it should look like this

(Attachment Link)



Very nice find: the blue/white livery GS1000S is called a Wes Cooley special in the US - they go for big money. A very original one just sold for over $15K.

[url]http://www.ebay.com/itm/1980-Suzuki-Other-/232350283672?hash=item361927f798%3Ag%3A-iQAAOSwYlRZKI8x&vxp=mtr&nma=true&si=ESxnEjUdWv%252FC3zxRPHnsazMTTRE%253D&orig_cvip=true&rt=nc&_trksid=p2047675.l2557[/url] ([url]http://www.ebay.com/itm/1980-Suzuki-Other-/232350283672?hash=item361927f798%3Ag%3A-iQAAOSwYlRZKI8x&vxp=mtr&nma=true&si=ESxnEjUdWv%252FC3zxRPHnsazMTTRE%253D&orig_cvip=true&rt=nc&_trksid=p2047675.l2557[/url])


Thats good to hear  :)
My one will need a complete engine rebuild, original exhaust system, original seat etc etc, i think i may have to put £2.5K in her to make her shine correctly  ;)
Luckily, i picked her up for £2,200  8)  So i guess, worst case she will owe me £5k when she's done.

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on July 31, 2017, 03:11:30 PM
Back to the GSXR  ;D

Despite having a couple of weeks off, not a lot of work has been done to the GSXR, naturally my wife saw it as a perfect opportunity for me to do a pile of jobs round the house  :-[

But some things have been done  :D

[attachimg=1]

Wheels and disc's have been refubed and refitted, and today i mounted some new tyres

[attachimg=2]

After much research and discussions on other forums, i have decided to have the frame/swingarm re-anodised, so its a road trip to A1 Anodising in Crawley in the morning ...

[attachimg=3]

More soon

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on August 01, 2017, 04:21:21 PM
Frame/swingarm delivered this morning for re-anodising  :)

Then i finally got back to the engine, prepared the cases ....

[attachimg=1]

[attachimg=2]

Ready to put the crank back in and button her up again ............ Tomorrow  ;D

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: loctite on August 01, 2017, 08:32:46 PM
looking good steve
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on August 02, 2017, 06:52:13 PM
Crank in ....

[attachimg=1]

Oil pump strainer and sump ...

[attachimg=2]

Fliped over for top case bolts ....

[attachimg=3]

All buttoned up and back in the engine stand ...

[attachimg=4]

Gear selector mechanism, oil pump drive and clutch basket next, then start on the pistons  8)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: GR400 on August 02, 2017, 06:55:53 PM
Looking great Steve  :)  I'm wondering how many bikes you can build in the time it will take me to do one!!
Title: Suzuki GSXR750 1985
Post by: Motty on August 02, 2017, 08:05:28 PM
That's a neat little engine stand

Sent from my XT1032 using Tapatalk

Title: Re: Suzuki GSXR750 1985
Post by: murp on August 03, 2017, 08:02:39 AM
Steve... did you see this


https://youtu.be/7Wc9jkUlZIM (https://youtu.be/7Wc9jkUlZIM)

Sent from my HUAWEI GRA-L09 using Tapatalk 2

Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on August 03, 2017, 08:41:31 AM
Steve... did you see this


https://youtu.be/7Wc9jkUlZIM (https://youtu.be/7Wc9jkUlZIM)

Sent from my HUAWEI GRA-L09 using Tapatalk 2

Hi Dave, no i dont thinks so, i'm downloading it now to watch later  8)

Thanks

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: allspeed400 on August 03, 2017, 12:35:28 PM
Just watched this and enjoyed it very much
thanks for posting it
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on August 09, 2017, 07:15:52 PM
Fastners .....

[attachimg=1]

Pistons !!!  (No Stukey, not those  :o :D)

[attachimg=2]

Fitted

[attachimg=3]

More later

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: tz750d on August 17, 2017, 02:57:20 PM
Great stuff this Steve - almost makes me want to do a 4 stroke next!
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on August 17, 2017, 06:45:52 PM
Great stuff this Steve - almost makes me want to do a 4 stroke next!

Cheers Don,

Not done much more recently as i've been busy with the day job  :(

Should be collecting the frame back after being reanodised, tomorrow and should have a little time to crack on with it next week  :)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: tz750d on August 17, 2017, 08:13:35 PM
Steve, who is your supplier for the nuts, bolts hardware etc?
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on August 17, 2017, 08:17:40 PM
Hi Don,

Obviously they are in the UK, but they are very good  :)

I've bought stainless for the GSXR so they dont tarnish too quickly  ;D

This is the company http://www.westfieldfasteners.co.uk/ (http://www.westfieldfasteners.co.uk/)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: tz750d on August 18, 2017, 11:13:07 PM
Cheers  :)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on August 19, 2017, 06:13:52 PM
Still busy with work, but got half an hour this afternoon

After a few 4 letter words  >:(  and a bit of jiggling about, the 'jugs' went back on  :D

[attachimg=1]

[attachimg=2]

next, to tackle this beast .........

[attachimg=3]

16 valves to lap in  :(

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: kawazonkey on August 19, 2017, 09:26:40 PM
Damn that's clean!
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on August 19, 2017, 09:56:19 PM
Damn that's clean!

Stripped by me, cleaned by TSR Dave  :)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on September 05, 2017, 04:41:45 PM
Back again with a few days free for the GSXR  :)

Lapping in 16 valves and then refitting them takes more than a moment  ::)

But is now revalved ...

[attachimg=1]

Tomorrow i should be able to complete the head rebuild (fit tappet arms, set tappet gaps) and maybe put it back on the engine  ;D

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: RD17 on September 06, 2017, 12:40:56 PM
Nice work  ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on September 06, 2017, 06:00:12 PM
More today  :)

Rocker arms fitted to head

[attachimg=1]

Then signal generator (sparks) so valve timing can be set

[attachimg=2]

Then 'On with her head !!'  :D

[attachimg=3]

Finally in with the cams and set the valve tappets

[attachimg=4]

She is now ready to be man handled back into the frame, lightest she could be allowing to set everything up.

Start preping the frame tomorrow

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: crip on September 06, 2017, 09:35:59 PM
great work on the 4 smoke, shame all that lovely engine detail will be tucked in behind a fairing  :o ;)
Title: Re: Suzuki GSXR750 1985
Post by: rsvr1000 on September 06, 2017, 11:50:36 PM
Mega read so far, well done  ;)
Title: Re: Suzuki GSXR750 1985
Post by: kawazonkey on September 07, 2017, 12:35:17 AM
It might be tucked away but we, and more importantly, him, will know it's the pups nuts.
Title: Re: Suzuki GSXR750 1985
Post by: stukey on September 07, 2017, 07:28:20 AM
looking good steve  :) :)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on September 07, 2017, 02:10:40 PM
A good mornings work today .....

First of all

Engine meet Frame,  Frame meet Engine ..  ;D

[attachimg=1]

Yes, the great design flaw with these early GSXR was that you cant fit or remove the airbox with the engine in the frame  :o

So first the airbox went in and with help from my mate 'Rattle' we put the two together  8)

[attachimg=2]

Up on a stand and secured, now i can get on with the build  :D

[attachimg=3]

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: RD17 on September 07, 2017, 02:14:16 PM
Oh yes - Look at that!! Looks so smart. How did the frame come out, looks great!

Cheers
RD17
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on September 07, 2017, 02:27:10 PM
Oh yes - Look at that!! Looks so smart. How did the frame come out, looks great!

Cheers
RD17

To be fair the frame is only OK, was a lttle dissapointed with the quality of their work, didnt clean everything up first.
Fortunatly most is hidden by bodywork. It may be just me but if i used them again i would thouroughly clean it all first  ;)

I'm sure it will look good when all done

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: RD17 on September 07, 2017, 02:56:40 PM
Oh yes - Look at that!! Looks so smart. How did the frame come out, looks great!

Cheers
RD17

To be fair the frame is only OK, was a little dissapointed with the quality of their work, didnt clean everything up first.
Fortunatly most is hidden by bodywork. It may be just me but if i used them again i would thouroughly clean it all first  ;)

I'm sure it will look good when all done

 ;)

Interesting, I have never had much joy with re-anodizing to be honest but as you said its all about surface prep and removing contaminants. Looking forward to seeing this bike coming together. Out of interest who are you using for the bodywork?

Cheers
RD17
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on September 07, 2017, 03:00:28 PM
Bodywork is already done and waiting  8)

Was all done by Tony Collins, quality painter, terrible timekeeper  :D :D :D

[attachimg=1]

[attachimg=2]

[attachimg=3]

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: RD17 on September 07, 2017, 04:19:23 PM
Bodywork is already done and waiting  8)

Cool!  Yes I know Tony  :D
Title: Re: Suzuki GSXR750 1985
Post by: 5port on September 08, 2017, 09:02:20 AM
Nice work Steve.  Don't think you mentioned what you did with No1 cyl?  I guess a new liner ? Cheers

5port
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on September 08, 2017, 05:43:50 PM
Hi 5port,

No i didnt reline the bore, i managed to pick up a low milage barrel and pistons for £60  :)

So i just rebuilt it with the low milage barrels and pistons, with new rings  :D

Bit more today, mainly rebuilt the clutch

[attachimg=1]

[attachimg=2]

[attachimg=3]

Did a few other bits, fitted starter clutch and cover, starter motor and Alternator.

Painted the special cam cover bolt heads too, so should be able to fit the cam cover and just about finish engine tomorrow.

Then i will rebuild the forks and fit the front end  :)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: 5port on September 08, 2017, 06:07:03 PM
Nice one with the low miles barrels and pistons!  ;)  £60!!  ;)

5port
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on September 09, 2017, 05:12:57 PM
Todays task was to complete and button up the engine .....

[attachimg=1]

All done (except drive sprocket) ....

[attachimg=2]

[attachimg=3]

Next task is to get her back on her wheels, starting at the front  :)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on September 20, 2017, 03:31:43 PM
Found a bit more time for the GSXR

Built up the forks

[attachimg=1]

and quickly fitted them with the bottom yoke

[attachimg=2]

Then down to the back to fit lower link and fix in top of shock

[attachimg=3]

Then after a certain amount of 'jiggling' i refited the swingarm

[attachimg=4]

Then in with the front wheel and mount the back on a proper jack

[attachimg=5]

Next will be back to the front to fit the anti-dive units and then 'hang' the front wheel from the frame in order to fully extend the front forks before filling with oil and fitting caps.  ;D

Need to start thinking about refurbing this too

[attachimg=6]

More soon

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Motty on September 20, 2017, 06:18:56 PM
I hadn't realised what a huge air box your GSXR is fitted with  :o
Title: Re: Suzuki GSXR750 1985
Post by: kawazonkey on September 20, 2017, 09:25:11 PM
That looks like the original exhaust to me. If it is it's worth saving!
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on September 20, 2017, 11:08:33 PM
Yep the airbox has to be put in the frame before fitting the engine !!!!!  ::) ::) ::)

and Yes it is an original exhaust, which is in good solid condition  :D :D

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: kawazonkey on September 20, 2017, 11:31:30 PM
Is this a low miler? Never seen one for sale with an original zorst as they all rusted away.
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on September 21, 2017, 12:41:24 PM
Is this a low miler? Never seen one for sale with an original zorst as they all rusted away.

 :)

For its age its not a high miler, engine has done 26,000 miles (I think), however i sourced the exhaust seperatly as it came with a stainless pipe fitted  :)

[attachimg=1]

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on September 21, 2017, 05:55:14 PM
Some more done today  ;D

Fitted Anti-Dive units, filled the forks with oil

[attachimg=1]

Then, fitted rear wheel to make her a 'roller'

[attachimg=2]

Then back to the front to fit subframe that carries the headlights and clocks

[attachimg=3]

Next job is to make one good set of headlights from these  ;D

[attachimg=4]

More soon

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on September 24, 2017, 02:51:08 PM
So i stripped down the two sets of headlights only to find that i didnt have enough 'decent' parts to make one good set. Need some new parts from Suzuki, so these were ordered  ;D

Then i moved on to the clocks, the bike was originally a Japanese import (with an MPH speedo fitted) top left in pic.

I'm rebuilding the bike to full UK spec, which doesnt have the fuel gauge in the clocks but also has a slightly different 'idiot light' set up because the UK spec bikes had a side stand switch/light and the Jap spec ones didnt. UK spec clocks on top right in pic.

[attachimg=1]

I've had to also order a complete set of bulbs as they are capless fittings, so none of my RD bulbs will fit  ::)

So like the headlights i'm also waiting for bits to build up the clocks.

Day job week next week, so more soon ish  :D

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: loctite on September 25, 2017, 10:25:40 AM
Great work bikes gonna be great
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on October 02, 2017, 03:47:21 PM
Day job done for a week or so,so its back to the GSXR  :)

Let battle commence  ::)

[attachimg=1]

More soon (i hope  :D )

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on October 03, 2017, 05:09:17 PM
Took most of the day but now they are rebuilt and as smooth as silk  :)

[attachimg=1]

[attachimg=2]

Got a small parcel from Suzuki today, so tomorrow i can sort the headlights

[attachimg=3]

and the clocks

[attachimg=4]

More soon  ;D

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: kawazonkey on October 03, 2017, 09:01:13 PM
Phwoar...carb porn  :D
Title: Re: Suzuki GSXR750 1985
Post by: twostrokelooney on October 03, 2017, 09:54:20 PM
Excellent detailing there Steve  8) 8)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on October 04, 2017, 05:20:18 PM
Thanks guys  ;D

Headlights and clocks today ......

[attachimg=1]

[attachimg=2]

[attachimg=3]

Hopefully fit them to the bike tomorrow, then start to fit my NOS loom  8)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on October 05, 2017, 04:44:55 PM
So today i mounted the headlights and clocks

[attachimg=1]

Then set the handlebars and mounted the switches and mastercylinders

[attachimg=2]

and finally the rear caliper

[attachimg=3]

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: GR400 on October 05, 2017, 05:39:32 PM
Looking like a motorbike now Steve. Lovely  :) Is this one to ride or display?
Title: Re: Suzuki GSXR750 1985
Post by: tz750d on October 05, 2017, 10:33:17 PM
Looking great Steve - like the new foam on the clocks - important detail
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on October 11, 2017, 04:08:41 PM
Hi Gary,

This one is for my 'pension pot' collection  8), its not really designed for us 6+ footers, its really quite small and cramped to ride.  ;D

Well, i am supposed to be in Japan now  ::) , but thanks to a nasty cold/bug i'm still here, finally feeling a bit better so i've got a few days to do some more on the GSXR  :)

Fitted the front calipers

[attachimg=1]

New NOS brake lines and then the first bit of paint  :P  Fitted front muddy

[attachimg=2]

Then started on fitting the second bit of paint, the rear light/tail section

[attachimg=3]

Should get a bit more done before rejoining the circus in Australia  8)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: RD17 on October 11, 2017, 04:39:58 PM
Coming along nicely  ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on October 12, 2017, 06:14:40 PM
A little more today  ;D

Worked on the rear end, fitting muddy, light, subframe, seat lock and various brackets etc etc

[attachimg=1]

[attachimg=2]

[attachimg=3]

I'm working towards fitting a new NOS loom, so trying to mount all the electrical 'points' that connect to the loom.

Hopefully a little more tomorrow

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Comms Guy on October 13, 2017, 11:14:22 AM
Steve, waiting in anticipation for the final result. Excellent as usual. :D :D
Title: Re: Suzuki GSXR750 1985
Post by: tz750d on October 28, 2017, 01:54:35 PM
Beautiful work Steve - love the NOS brake lines !
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on November 09, 2017, 06:57:11 PM
Hi Guys,

Been away for nearly month, so nothing much done.

But back now and i had an hour today, so after much fer fer fiddling about, the carbs went back on

[attachimg=1]

Now a little bit of 'Proud Grandad' time.

My 6 year old grandson made his debut for Arsenal (under 8's ) tonight .....................

He only went and scored in the first 5 mins  :P :P :P

[attachimg=2]

More soon

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: stukey on November 09, 2017, 07:00:31 PM
Great job as always steve and well done to the lad :) :) :)
Title: Re: Suzuki GSXR750 1985
Post by: GAZZATT2 on November 09, 2017, 08:55:26 PM
looking good
your grandson has chose a good team  ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on November 27, 2017, 09:38:23 PM
Finally finished all my 2017 work so will be back at the 'slabby' tomorrow  :)

However, i'm all ready preparing stuff for my next project, because of the lead times i get the chrome sent out and the paintwork sent out too (both of these normally take around 3 months).

Shock and horror, Tony Collins turned round my paint in 4 weeks  :P :P :P

So i picked it up today ........

[attachimg=1]

[attachimg=2]

GSXR tomorrow ...

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: kawazonkey on November 28, 2017, 09:37:31 PM
WOW!
Title: Re: Suzuki GSXR750 1985
Post by: Motty on November 28, 2017, 10:24:43 PM
The paintwork looks fantastic

Sent from my XT1032 using Tapatalk

Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on December 04, 2017, 08:47:04 PM
There has been some progress, but not a lot, because now i'm done with work my wife now thinks i'm her personal slave  :-[ :o :(

Doing a few things at the moment :-

Refurbing rear brake master cylinder.
Refurbing and painting oil radiator
Refurbing the exhaust system

And, my most disliked job ........... wiring !!

Fitting new 1986 NOS loom  (the bike is an '85 and they are different, so expecting some issues)

[attachimg=1]

Not sure this is right  ::) ::) ::)
Better find a service manual

[attachimg=2]

More soon

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: kawazonkey on December 04, 2017, 09:07:40 PM
Not a fan of wiring either, hope it goes well.
Title: Re: Suzuki GSXR750 1985
Post by: Motty on December 05, 2017, 01:04:23 PM


There has been some progress, but not a lot, because now i'm done with work my wife now thinks i'm her personal slave  :-[ :o :(

It comes to us all eventually :-(

Sent from my XT1032 using Tapatalk

Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on December 07, 2017, 06:19:06 PM
OK, update on the wiring  :-[

I think i now have it sorted apart from the last section behind the headlights  ::)

Unlike our beloved RD's, the main 'clump' of wires is not in the headlight bowl (there isnt one on the GSXR)

Instead the main 'clump' is behind the headstock, in front of the fuel tank and above/behind/below the coils  ::)

So it goes in here ..........

[attachimg=1]

In between the coils are the headlight relays (different from the 85 loom)

This 'spur' of the loom gets connected to the wires from the left and right switches (yellow and black connector blocks) and when connected is hidden above/between coils, so the tank will go in.

[attachimg=2]

A seperate piece of loom connects the back of the headlights to the two relays between the coils (not in pic yet but also has to go in here).

The back of the loom passes  round the side of the airbox and is then tie wrapped under frame tubes (frame cant be seen when panels are on)

[attachimg=3]

It then passes across the frame and then hangs down on the otherside where it connects to fuse box and rear brake light switch.

[attachimg=4]

This loom is doing my head in but i think i'm getting there, just the front section to do.

A few other bits are in process, here oil radiator in primer

[attachimg=5]

More soon

 ;)

Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on December 08, 2017, 05:22:34 PM
I continued with the wiring saga today, with some sucess  ;D

Fed the switchgear and headlight wiring behind the headstock.

Conected everything up and had no wires left over  :P

Poked it all away above/behind the coils and it looked like this ....

[attachimg=1]

The fuel tank has to fit down inside the frame rails and not foul the wiring, so checked it with my spare tank

[attachimg=2]

Next job was to build up the front right footrest/brake system/peddle

[attachimg=3]

[attachimg=4]

And fit to the bike

[attachimg=5]

Next i wanted to sort out all the wiring in the middle of the bike, so to do this you need to build up the battery box with its electrical componants ................

Starter Solenoid and fuse box

[attachimg=6]

and CDI unit

[attachimg=7]

Then wrestle it into the middle of the frame and connect everything up

[attachimg=8]

[attachimg=9]

A major step forward, no spare wires here either.

Just the very front electrics to sort next  8)

More soon

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: kawazonkey on January 04, 2018, 10:00:48 PM
Just spotted this. Never seen one before!

https://www.ebay.co.uk/itm/Fujimi-Yoshimura-Suzuki-GSX-R750-1-12th-Model-Kit/302590517022?hash=item4673ccdf1e:g:3WoAAOSwvApaQU5- (https://www.ebay.co.uk/itm/Fujimi-Yoshimura-Suzuki-GSX-R750-1-12th-Model-Kit/302590517022?hash=item4673ccdf1e:g:3WoAAOSwvApaQU5-)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on January 05, 2018, 04:44:21 PM
Seen that model GSXR, tempted  :D

Anyway, been a while, hope you all had a great Christmas and New Year  ;)

Back to the GSXR, great strides were made today  8)

Next step was to connect up the last bit of the loom, behind the headlights

[attachimg=1]

Connected everything i could see, but had a few connectors over  ::) ::) ::)

[attachimg=2]

[attachimg=3]

After quite a bit of research i discovered these connectors are for something called the NEAS system (antidive and damping in front forks), which was not fitted to my '85 bike. So dont need them  ::)

So then i connected a battery to the loom  8)

The bike currently is dry and there is no exhaust or oil radiator fitted, so all i wanted to do was check all the electrics worked ...............

A gentle prod of the starter button, and ..... Yes !  the engine turned over nicely, if a little slowly (dry rebuilt engine and dry clutch).

Checked each HT lead/plug for a spark ........ Yes, all good.

Then the other electrics ......... Low beam, High beam, headlight flash, indicators, tail light, horn, neutral light, oil light ................................................

All worked perfectly  :D :D :D

Only problem i found was that the side stand switch light stays on, even when the switch is closed  :-[ , so i guess this is probably a short in the idiot light cluster as the loom and switch are both NOS.

Gotta say, i'm really pleased, time now to finnish her build now i know all the electrics work.

Happy Days  ;D ;D ;D

[attachimg=4]

More soon

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: stukey on January 05, 2018, 05:16:02 PM
looking good :) so what's the next project? :) :)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on January 05, 2018, 07:38:54 PM
looking good :) so what's the next project? :) :)

Hi Neil,

Next project is probably this ....

[attachimg=1]

or maybe this ....

[attachimg=2]

or maybe this ....

[attachimg=3]

2 Four strokes or a two stroke mate  ::)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Motty on January 05, 2018, 09:22:28 PM
Looks like there is no shortage of possible projects!

Sent from my XT1032 using Tapatalk

Title: Re: Suzuki GSXR750 1985
Post by: stukey on January 05, 2018, 09:33:52 PM
I still have a few  bikes  in the shitty shed ;)
Title: Re: Suzuki GSXR750 1985
Post by: GAZZATT2 on January 05, 2018, 09:45:43 PM
you won't have time for the TDR Steve

ill be happy to take it of your hands
Title: Re: Suzuki GSXR750 1985
Post by: kawazonkey on January 05, 2018, 11:44:11 PM
I vote for the GS litre. I had one like that, what a hoot. Bullet proof engine and it handled like an Elephant wearing roller skates whilst on acid. Great bike!
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on January 06, 2018, 09:04:23 AM
 :D :D :D :D :D :D :D :D

Thanks for your comments guys.

Sorry Gazza the TDR is going nowhere  :P

Undecided now on what will be next  ::)

There is still a few weeks in the GSXR yet tho

More soon

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Alvin Sparklug on January 07, 2018, 07:53:44 PM
 ;D ;D ;D loving this build.   :D
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on January 14, 2018, 03:02:32 PM
Finally got back in my shed this morning.

Then spent 2 hours building, rewiring, fitting the indicators and checking they worked

[attachimg=1]

Then fitted the side stand switch (as per UK spec)

[attachimg=2]

Only small hickup this morning was fitting the rear brake light switch ..... spade connectors on loom, bullets on switch  ::) ::) ::)

[attachimg=3]

More soon
 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on January 25, 2018, 06:02:03 PM
Been a while but got some time today on the GSXR  :)

Fitted chain

[attachimg=1]

Fitted brake and clutch hoses to the master cylinders, then re fitted clocks and headlights

[attachimg=2]

Then i could add some more 'paint'  ;D

Rear seat panels

[attachimg=3]

[attachimg=4]

Grab rail ....

[attachimg=5]

and finally the rear seat section ....

[attachimg=6]

Next will be fitting the oil radiator and the exhaust  :D

Looking sweet now tho  8)

[attachimg=7]

More soon

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: loctite on January 25, 2018, 06:50:22 PM
Won’t be long now,,looking great
Title: Re: Suzuki GSXR750 1985
Post by: Motty on January 25, 2018, 07:50:58 PM
Looking like it's nearly there :)
The Wendy House looks like Mrs SFBrain needs to give it a tidy up

Sent from my XT1032 using Tapatalk

Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on January 26, 2018, 08:22:43 PM
 :D :D :D :D

The wife is not allowed in the Wendy House Motty, but you are right, its about due for a spring clean  ::) ::) ::)

A little more today

Front left footrest and chainguard fitted

[attachimg=1]

Weather was better today and warm enough (with the wendy house heater) to do a bit of painting ...

[attachimg=2]

A few dents to sort out in the heat shield, then a polish

[attachimg=3]

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: kawazonkey on January 26, 2018, 10:56:51 PM
That is one seriously good looking bike.
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on January 31, 2018, 02:35:20 PM
Getting there now  ;D

Time to fit the radiator and this ..............

[attachimg=1]

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on February 06, 2018, 01:04:32 PM
OK, this morning i pressed on with the GSXR

Time to fit the Zorst  ;D

All the bits needed ....

[attachimg=1]

[attachimg=2]

A bit of 'Jiggling' and .....

[attachimg=3]

[attachimg=4]

Next job is fit the radiator ...

[attachimg=5]

Looking like a proper bike now

[attachimg=6]

More soon

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on February 06, 2018, 04:41:22 PM
A little more this afternoon ...

Mounted radiator

[attachimg=1]

The exhaust has a mounting bracket that is located on the bottom rear engine mounting bolt, now the exhaust is on the bottom engine bolt could be tightened up.
This then ment i could finish up the front sprocket cover, clutch activation cylinder and finally the gear change linkage.

[attachimg=2]

More soon

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on February 10, 2018, 11:50:13 AM
Had one of those days  ::)

Fitted the oil feed pipes to the radiator

[attachimg=1]

Just left with little jobs to do, here the tank mounting bracket

[attachimg=2]

So, i thought i was just about ready to try the big start up.  ;D

All i needed to do was beed the hydraulic clutch, which has a normal master cylinder on the handlebars and an activation cylinder to push the clutch push rod. The main reason for this is that the engine has been rebuilt and is quite tight and the clutch is engaged, to make it easier on the starter motor it will be better to have the clutch held in while starting, causing less drag  8)

Then i found that my new bleed nipple for the activation cylinder is a 7mm nipple and i need an 8mm nipple  :-[

So now i'm waiting for an 8mm nipple in the post (also need to go buy 4 litres of 10/40 engine oil)

More soon

 ;)

Title: Re: Suzuki GSXR750 1985
Post by: mr sheene on February 10, 2018, 06:06:22 PM
shes looking good mate
Title: Re: Suzuki GSXR750 1985
Post by: kawazonkey on February 10, 2018, 09:17:10 PM
Get a video of the start up if you can, would love to hear her burst into life  ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on February 24, 2018, 12:47:04 PM
Hi All,

A few have asked what happened on the GSXR startup ??  :P

Well, sorry to say i havnt tried yet  ::)

I have been a bit busy with the day job and even busier with preparation for the new season, also the 'good lady' and my family have also been occupying most of my time, so i really havnt had time for the GSXR.

In the meantime a few extra jobs have been arriving  ::)

An RD400C engine for rebuild

[attachimg=1]

and an early Honda SS50 engine, also in for a rebuild

[attachimg=2]

Hopefully i will get to start the GSXR very soon

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on February 28, 2018, 07:42:19 PM
 >:( >:( >:( >:(

Ok, tried to bleed the clutch a couple of days ago, after loads of swearing i found out my slave cylinder is F**ked  :-[

A new one arrived today, so if my 'Wendy House' is not snowed in i will try to fit it tomorrow.

In response to an earlier post, i have now decided what will be my next project ....................

Not the 'Ice Cream Van' GS1000S, but Helga !! (she is German)  ;D

[attachimg=1]

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: GR400 on February 28, 2018, 08:28:49 PM
Looks very tidy as is Steve.  Is it a full restore?
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on February 28, 2018, 08:34:34 PM
Hi Gary,

No, it will be a partial restore, paint will be redone (in the correct colour blue), will be converted to UK spec (headlight, speedo etc).

Carbs will be completely stripped and rebuilt and a general tidy up.

Then MOTed and registered here in the UK.

Then ridden  :D

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: stukey on February 28, 2018, 11:39:00 PM
They go better with a 350 motor in ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on May 16, 2018, 03:52:50 PM
Hi Guys,

I know it has been a long time, work, family etc etc have meant i havnt had time to do anything to the GSXR  :-[

Until today !!!

This morning i made the first attempt to start her up ..........

She Lives !!!  :D :D :D

[attachimg=1]

Smokie air shows her running, couldnt take a video with thumb on the starter, left hand holding the clutch in and hovering over the kill switch, just in case  :D

She is running a little rough, this is probably due to the carbs having been completly stripped and needing balancing, and i do think the spark is quite weak and there is a slight miss fire ??

Some or all of this could also be down to the engine being completly rebuilt and consiquently full of oil in bores etc etc

However, i did run her up 4 or 5 times and got her proper hot, and ................. no leaks !! ;D

The only non functioning thing was that the rev counter didnt work (which is electrical), so may be a duff rev counter.

Next job will be to balance the carbs and investigate the rev counter.

Sorry again for the delay but life/work/familyget in the way sometimes  ::) ::) ::)

Later
 ;)
Title: Re: Suzuki GSXR750 1985
Post by: Motty on May 16, 2018, 05:54:51 PM
Great news, another old bike saved :)
It's been an unusually long gap between the updates, you must have been very busy ;)
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on May 16, 2018, 06:41:25 PM
Great news, another old bike saved :)
It's been an unusually long gap between the updates, you must have been very busy ;)

Yes Richard, work has been very busy (Qatar, Argentina, Texas) and my wife has had me doing 'house' things, so never got any 'boys' time.

Hopefully i will get a bit more shed time now  :)

 ;)
Title: Re: Suzuki GSXR750 1985
Post by: kawazonkey on May 16, 2018, 10:08:57 PM
Brilliant news. Would love to see it in the flesh.
Title: Re: Suzuki GSXR750 1985
Post by: Sfbrain on May 16, 2018, 10:23:44 PM
Brilliant news. Would love to see it in the flesh.

Certainly a step forward, but still things to do .....

Running a little rough which i think is down to two things, 1. the carbs need to be balanced, and 2. there is an intermittant mis fire, which i think is down to a dodgy battery and the original coils/leads need checking.

Also the tacho isnt working (its electronic), and has a feed off one of the coils.

So some investigating to do yet, but i was naturally pleased when she burst into life  :D

 ;)