1989 Suzuki GSX750FK Renovation!

[djrose007]

Had this on the old OldSkoolSuzuki forum and also TMB Forum but it's time it started afresh rather than clogging up the OSS Facebook pages.
I'll probably still post on the FB page when I need some quick advice, which is inevitable!

OK, Started in May 2009. After being made redundant from Nortel Networks in the March I decided a motorbike rebuild might be a good experience for me and give me something to do. For one reason and another, details on my blog, I did very little work for 4 years until I could get going in March 2013.

I think the engine hadn't run for about 10 years, the back had been hacked off to make a streetfighter but an awful job had been made of the hacking. Had some bits and pieces but no light, instruments etc. Seat base was there but no padding or covering. I got a new seat off ebay, never thought of getting the old one recovered but you live and learn!

Current status is;

• Engine is running, albeit a bit lumpy but I need to run it for a good while. Only run it for a few minutes, twice, so far.
• Frame needs welding where it was cut
• All the electrics need to be sorted. Looms are there but many wires have been cut off so may need new looms.
• Front Brake Calipers were in a pretty bad way and I've stripped, cleaned and polised. Awaiting new seals to put them back together.
• Need to remove rear caliper and clean it all up as well although it is working. Front calipers were seized.
• Want to get it on the road, MOT'd and then I'll spend even more money on it with some new brake pistons, mirrors, still need a windshield.

Hopeful that it will be a successful project and go from this - First time I saw it



To this, an advert for a GSX750FK on Gumtree.

[m4sterguru]

A lot of work in there bud, and money, i like 750's very much, even more when they fit 1127 engines on it.

[davecara]

I should be breaking one of these soon, what bits do you need for it?

[djrose007]

Hi Dave, 
I'm not really sure at the moment. I was very lucky in picking up a load of stuff in one go when I was after the twin exhausts and fairings. When I went to pick them up (from Gloucester to Stamford, Lincs) the guy said he would throw in a load of other stuff like the grab handle, coloured mudguards, light and instrument cluster, rear light and rear sub assy, he was very generous but I think he was more concerned that it would go to a good home rather than the money. All of that cost me £180.00.

I haven't even looked at the electrics yet so might needs some bits in that direction. The loom has been cut off short as the previous owner was going to make it into a streetfighter so I might need a new loom and electrical components.
Problem is I have no idea what makes these things tick yet, I'm learning as I go along.

There's bits on there that I don't even know what they do, or what they are! E.G. couple of little round things near the battery.

Two components on offside of bike below the battery.

This one is on the nearside beneath the battery. The red electrical tape is because the rubber holder is split where it slots onto the metal tab where it fits onto.

One of the offside components

The other offside component

If you have looked at the blog you will have seen what a mess it was. On the back, where the sub frame bolts on, he's welded a plate to fit an LED rear light. I'm going to cut that off and replace the sub frame and an original rear light etc.


Thanks for the offer of bits, please let me know when you are breaking it and I'll see if I know what I need by then.
email address is [e-mail]

Cheers
Dave

[djrose007]

Quick update today, 21 April 2013.
Got the bike out of the garage so I can work on it outside as the weather seems to be picking up. Rain forecast for this afternoon but hope it's not going to be prolonged!


I think I've identified that the blowing exhaust is due to the excessive welding around the flange. See photo enclosed.
I've removed it again to file more off to get it more even around the whole thing for the bracket to fit onto.


I did think it might have been out of line because of the end pipe that has been welded on, photo enclosed for this as well, but it appears to be lining up ok, just the lumps of welding in the way.

[Ash]

Do you want this moving to projects?

[djrose007]

Apr 22, 2013 6:11:32 GMT Ash said:

Do you want this moving to projects?

That might be a good idea, yes please.
Cheers
Dave

[djrose007]

Thanks yet again to Simon Frankie Evans for letting me know about the plates that fit onto the exhaust manifold. I thought it just needed the gaskets but lack of plates is probably why the far offside one is still blowing.
Received the plates from Robinsons Foundry, removed the exhausts and will refit after the welding of the frame has been done. Hoping that will be bank holiday Monday.

[djrose007]

Started the welding today, six points in all, two of them pretty bad with gaps.
Photos of the bits to be welded.









Now the really bad one looks like this although it's not yet finished plus going to weld plates across the gap to strengthen it, the others still to be done.




Also cut off the plate that had been welded onto the back when the intention was to make it a StreetFighter bike (not by me!).



Now looks like this 

[djrose007]

Rough couple of days weather-wise so just made plates to weld over the bottom parts of the frame where they'd been hacked off.
Invested in an angle grinder yesterday which makes life so much easier than hacksawing and filing!

[djrose007]

Apr 18, 2013 22:26:35 GMT davecara said:

I should be breaking one of these soon, what bits do you need for it?

Hi Dave, I think I'm ok for bike parts, it's stuff like bolts I'm short of but ordered a box full of bolts from ebay after a couple of pointers from the facebook page.
Let us know through the facebook page when you put stuff up for sale and maybe something will grab my attention that I hadn't thought of.

I was short of a load of stuff but won Exhausts and fairings on ebay and when I travelled from Gloucester to Stamford (Lincs) to pick them up he threw in a load of other stuff including headlight/instrument assembly, rear light, grab handle, rear sub frame, and more!



Cheers
Dave

[djrose007]

Not done much the last few days but today, Saturday, I used my new angle grinder to get rid of the superfluous lumps of welding on the exhausts. Should fit better when I put them back on after the frame welding has been done.

[djrose007]

Still not got the welding done so spent some time on the front end electrics. Headlight, dip and high beam, works but problem with the indicator repeaters. Could be earth so some investigative work to do on that plus check out the wiring diagram to make sure I've got the right connections, might be a good idea!

[djrose007]

Since the last post I've made some progress in finishing the welding, getting all of the rear lighting working, got indicators off ebay.
Front end all seems to work, although I can't yet test the speedometer after fitting a new cable as it's not on the road.
Refitted the rear wheel and brake caliper after the welding.

Engine runs but runs out of fuel after a few minutes. I'm going to swap the pipe for the vacuum from in between carbs 3&4 to 1&2, maybe it's the diaphragm but I'm guessing.

Been updating the blog

[djrose007]

Had a thought about the fuel running out - Wonder if I'm running it a bit low and so when I get the chance to get it outside again I'll put more fuel into the tank, or maybe try it on the 'reserve' tap setting. I hope that's all it is but need to investigate a bit further.

Electrics on the front end appear to be ok but haven't yet wired up the indicators or the sidelight bulb. I didn't have a sidelight bulb at all but Simon 'Frankie Walney' Evans found one in his box of bits and sent it on to me, have to say he's been particularly brilliant in helping me out although all of the advice I've had from everyone has been great.