carl_87

Winter is coming and the bike is tucked away in the garage. It generally behaved well this summer, but i need to take a look at repairing or replacing the exhaust system, one header is leaking due to it looking like a rusted swiss cheese in places. Idle is a little low when cold and a little high when hot but it's manageable, but carburettors would probably like a competent tuning. Managed to drop the damn thing while moving it in the garage and busted the clutch handle, oh well. We'll see what gets done this winter, i have a new long-term project due any week now that will probably require some time and attention (the diaper-sporting kind). Other than that, all quiet on the northern front. Cheers!

Time has been lacking, i have moved yet again and am in the middle of restoring something bigger, namely a house. However, i found the time to do the finishing touches and get an MOT booked, today was the big day. Lesson learned: quarter full on the fuel gauge is actually zero. Good to know, luckily i had lots of time and got a morning jog. Almost, but not quite, a clean bill. MOT guy wanted to see a additional red reflective device, easy fix. Meaning, we are now good to go! We are indeed going, and it is good Now, i don't plan any more garage projects with this bike for now, we'll see if i find the time next winter to get the frame sand blasted and painted, and perhaps give the engine some cosmetic care. Thanks everyone for the help and hope you've enjoyed the project so far, i sure have

Thanks, it took some archeology work but under all the muck, there turned out to be a bike. I hope you like the updates, i sure am enjoying this project. Brake lines arrived and installed, great fit up front, less great in the back (a bit too long) but it'll work. Steel braided but with a black cover for a stock look. Things left to do except an MOT are mainly cosmetic. The frame has lots of surface rust and the engine has paint peeling off in all sorts of places. I didn't plan on doing that this winter though, maybe next. It’s about time this bike is ridden a little this summer

The forking things are done New seals, new oil and gave them a blast in the cabinet and a few coats of paint when i had them disassembled, turned out nice. Have not ridden yet, only manhandled the bike in the garage, but shocks seem to not leak anymore. Now i'm waiting on the new brake lines..

Thanks Tony

Evening fellas, I am disassembling the front forks to change out the leaky seals. It's going well, but i ran in to a little snag; This here aluminium cone fell out of the first fork. I was more careful with the second one and figured out where it came from, but i am not sure about the direction of the cone. Does anyone know? I would think it's the first option, but the exploded view in the service manual is not very clear.. New brake lines ordered, btw. Decided not to do the diy way, found a kit at a motorcycle shop. First option Second option:

Hej och välkommen! It should look something like these; https://www.fastfromthepast.com/fork-anti-dive-bypass/suzuki-anti-dive-bypass Regarding the clutch-thing, it looks to be pointing in the same direction as mine is. Do you have clutch slipping problems?

Right, sprocket cover it is I might go the DIY way, i did some Youtube'ing and like you say, it doesn't look like rocket sience!

Ordered seals for leaky front forks, waiting on them. Does anyone know if it's possible to buy a complete brake line kit, or is the best solution to just take all the measurements and custom order them? Some cleaning and vinyl-shine-goop breathed some new life into the seat. Sad clutch cover. Happier clutch cover after blasting and priming. Happy clutch cover. The obvious problem is, once some bits start looking nice again, the bits that previously blended in with the overall barn-found look suddenly look horrible, but i guess that is a classic problem with restorations.

Got the rear tyre sorted, it took a quarter of the time compared to the first one, and the result was better. A fivefold reduction in swearing as well. Did a bit of cleaning around the rear swing arm. After: Before: Purchased a small sand blasting cabinet, i have begun blasting some odd bits. Thing to do before putting more miles on the bike, new brake lines and get the leaking front shock sorted..

A little update, i have been in the process of moving so there hasn't been much time in the garage, but today i could squeeze in a few hours. New Pirellis, first time i have tried putting a tyre on a rim with tyre irons. Harder than i thought but it worked out with some harsh language. Did the starting gas trick to set the bead, worked like a charm. Will see if i can get the rear wheel sorted tomorrow. I was tempted to put a lot of effort in making the rims look nice but the advice given by you fellas to prioritize getting her running and MOT'd kept ringing in my ears, so that will have to wait a bit. New round black thing up front. Cheers

Beautiful ads! "Newly excercised (in lack of a better translation) - 22kg lighter, 4 hp ("horses") stronger" and "GSX 750 - The trend setter" (Trend creator to be precise, but i don't believe that's the proper expression)

Thanks a lot Cap'n! E17 it is then

Yep, they are closer to bakelite than rubber..like you said they are probably legal but definitely dangerous. On the bike right now, front 100/90 R16", and the rear 130/90 R17". The rear tyre is actually chafing a little against the metal "support bar" that runs from the caliper to the frame, and looking at the specs in the service manual, 120/90 R17 seems to be the correct size so i guess i'll go for that. Does anyone know what E06, 24, 27 and "The others" refer to?

I'd be tempted to say that the bike is acting better and better. I've put a few miles on it, here is a pic from today. Cheers

You were absolutely right, the thing holding the cover in place was just the gear lever shaft. Anything else was pure imagination on my part. With a lot of WD40 and wiggling, it came loose. The shaft does however have it's clip in place, and doesn't move in and out more than about a millimetre so i guess i'll have to take a look on the RH side around the clutch area. Old n dirty Edit, update: Turns out i don't have to open up the RH side after all. I cleaned out some of the gunk and put the cover, gear lever and whatnot back together, i figured i'd check she would shift like she did before atleast. Turns out she does a lot more now, i'm not quite sure what was rusted stuck that came free but something did, hooray! So basically, the bike runs now. Starts without too much hassle, revs, shifts and brakes. Tons of things left to do obviously, but we are sure getting somewhere

Correct, behind that rectangular cover is that strange locking washer. @wraith, i have all the bolts loose and the gear lever, but there is something still holding on from the inside, something that flexes a little bit. I'll see if i can find the time this evening to figure out what's what!

I figured i'd take a look where the gear lever sits and see if i could find any obvious reason why the bike won't shift above 2nd, but i'll need the cover off sooner or later anyways. I have loosened the bolts for the cover but something is preventing it from coming off, do i need to unscrew the clutch cable where it enters the housing? (Picture)

I can't for the life of me figure out how to do away with this locking washer-gizmo so i can get this cover off..and i don't want to break anything by applying more force to it..does anyone have any pointers? The repair manual says to "Flatten the washer" but i don't understand how.. Cheers

PanzerWomble was kind enough to gift me a service manual and it has been great to have so far! Do you mean on the LH side of the engine where the gear lever and clutch cable resides, or the RH side where the clutch lives?

Update: Put the airbox and the carburators back in, and took the bike for a spin. Now we are getting somewhere! She revs without any issues now, y'all were of course right about the reason for the bike not revving past 3000 before. I dared not rev past 7000, for no other reason than being gentle on the old girl... Next issue is not new, i noticed it on the previous test runs, but was of lower priority: it's impossible to shift higher than 2nd gear. The shifter feels completely stuck when going for 3rd, i tried applying some extra force with the foot but no luck. I'll do some resarch on the forum and the interwebs but if anyone want to point me in the right direction, i'm glad for the help! Cheers

Yeah i'll take care not to let this project grow out of proportion. I'm going to focus on getting it to run properly and on the brakes, and after that i'll see what to do about the rest. Like you said it ran when it was put away so i'll see if i can get it back to that stage.

Oh, ow. Looks like i'll have to hot-glue the airbox back together! I come from the land of fuel injection, manifold absolute pressure sensors and idle air controls and did not for a second consider that running without an airbox could have side effects other than the air not being filtered..but after reading up on the subject for a few hours, i'm beginning to understand. A week ago, i had no idea that vacuum controlled carburators even existed..it's certainly a learning experience! I appreciate the help and the input

I did a new compression test on number 3 and 4 this morning with the engine cold, and i got the same good results as yesterday, hallelujah. I was hoping you would not ask..i may or i may not have dismantled the airbox with a heatgun and a knife when i lost patience with it during the initial teardown. I figured i'd run four separate pod filters instead. Today i picked the carbs apart, i'll do cleaning some time in the next few days. The jets all look good, as in i can see the sunlight through them but i'll give them some care. The rubbers did not have any obvious tears or holes, but they do look a bit dry around the edges and show signs of cracking. They are somewhat flexible but not very, hard to tell since i have never worked on diaphragm carbs before.. could this be related to the bike's unwillingness to rev past 3-4000? Edit: the slides all come down in a smooth motion if i push them up by hand. None of them falls down faster than the other, and none of them come slapping down.