77 Suzuki GS750 Build

[Reid]

I got a set of stepped wheel spacers when I put a KX wheel on my XS just trim them to length.
http://www.cheneyengineering.com/FWheel.shtml

[Greenmachine]

Out of town this week for work so I've been looking for bearings online. Found these http://www.bocabearings.com/bearing-...12-MR62032RS58 according to what I found the stock KDX hub has 40mm OD 12mm width, these have 40mm OD 12mm width and 5/8" ID so it should work. The GF said that the wheel,showed up on tuesday so once I get home I'll measure to make sure but I think it will work.

So I'll have a 21" drum wheel that has better breaking power than a mini drum and looks better than the stock disc setup for $35. Plus I don't have to clutter the bars up with an ugly master cylinder either.

[Greenmachine]

Sorry for the lack of updates, between working out of town and moving I haven't got much done on the bike. Did get my KDX 21" wheel and threw it on with the stock forks. I think it looks nice.







Going to try to fab up the top motor mounts tonight.

[Greenmachine]

Finished up the top motor mounts tonight. Made a template out of cardboard and cut them out of 1/4" plate. Cut them into 3 pieces and clamped them to the mounting points on the frame and motor, then I welded the middle pieceback in place.

[Greenmachine]

Got the rear cross braces for the fender supports and seat spring mounts in place. Radiused the rear fender to match the 18" tire a bit better.





Also spent some time with a grinder and a file to clean up the welds on my springer. Still needs a bit of touch up but it should turn out pretty good.

[Greenmachine]

Made some progress today, built a new battery tray out of 1/4" material. It's probably a bit overkill but it works



Weld shot, getting better, a bit of overbuild on the bottom but not bad I guess.


Cut some 5/8" round down and drilled and tapped 2 pieces to make mounting bungs for the fender



Welded to the frame on the centerline



Using the lowbrow fender strut kit drilled the fender for the top mounting bungs. Forgot to take pics of the bottom mount but I drilled the frame and welded the threaded bung inside of it.



Bent up the rod with my vise and a torch and welded them up after some very scientific eyeballing. They aren't perfect but they are close.





Cut the mounts and brackets for my mids out of 1/4" x 3" plate. Tacked them together so I could drill them out on the drill press prior to welding on the frame to make sure I got the same centerlines for the bolts.







Cut them back apart and welded the mounting points to the bottom frame rail



Just waiting on the pegs so I can drill and tap the mounts and install.

[Greenmachine]

Thought long and hard about the brake stay setup. I cut the caliper mount off of the stock one and decided to use a helm on the other side. Cut some 3/8" round stock and threaded the ends.



Drilled through the frame so I could slip the 3/8" through and plug weld it from the back side. Slipped the heim over the threaded end and then welded the piece of round that's threaded into the heim onto the stock caliper mount bracket. Came out pretty clean. I will weld the other side of the rod where the heim attaches once I get the wheel out of the way and clean up the plug weld on the other side.





Overall shot of the rear of the bike with fender and brake

[Br4denJ]

I am also building a Gs, and I am curious to see how you are going to mount your foot pegs and shift linkage. I am having troubles with this part because the Gs motors are gigantic!

Could you share details when you get to this part?

Also, how did you get the springer to work with your neck tube?

The bike looks great!

[Greenmachine]

I am also building a Gs, and I am curious to see how you are going to mount your foot pegs and shift linkage. I am having troubles with this part because the Gs motors are gigantic!

Could you share details when you get to this part?

Also, how did you get the springer to work with your neck tube?

The bike looks great!

I'm not doing forwards, I'm just doing mids and I'm keeping the stock shift lever. The brake pivot and master cylinder will take a bit of fab but not much. Thought about forwards but the width of the motor made me choose mids.

As far as the springer goes the bottom plate of the springer is threaded so I'm just having a machine shop turn me a new stem that I can thread into the bottom clamp and retain the stock GS bearings.

[Greenmachine]

Built the coil mount tonight. Fabbed it out of 1" x 1/8" flat stock, it's pretty basic but it should work.



Made some threaded bungs out of 1/2" round stock and welded them to the vertical seat post.



Pics with coil mounted







Going to spent the weekend on the front legs of the springer so hopefully I can get it completed and installed. Pics to follow

[murraydo15]

Awesome

[drenfro22]

I like the way this is coming along. I have a GS750 I'll be building sometime soon, so it's good to see someone tackling this bike.

[Greenmachine]

Got the new front legs of the springer on. Cut the old ones off and drilled the bottom of the plate about half way through so the new bar stock would be captured by the plate as well as my weld. Got the new legs mounted and the springs back on. Sorry forgot to take pics of the process.

Cut the old stem out of the stock triple and ground it down to fit in the springer bottom tree.







Spent a lot of time and about half a tank of map gas preheating the bottom plate of the springer and welded the old stem in place. The stem was hollow but I found out that a piece of 5/8 round bar fits perfectly in there so I am going to slug it for added security in the future.





The bike with the springer is so long I had to roll it outside to get a picture of the entire bike in one shot.













Got to get the rear master cylinder mounted tomorrow for the rear disc and try to figure out what wheel I can run on the front as the springer is too narrow for the 21" kdx wheel and I want a front brake. Looking like a mini drum may be my only option.

[Kraz1]

Did you ever come up with an 844cc Wiseco Kit? They are not in stock currently. Let me know if I can help you with that..

Woody

[dirtbag]

Lookin good..

[Kraz1]

Links to online bearing suppliers that are affordable? The bearings seem like the easier solution as long as I can get the correct fit.

Thanks

CLICK -------> World Wide Bearing

[Greenmachine]

Did you ever come up with an 844cc Wiseco Kit? They are not in stock currently. Let me know if I can help you with that..

Woody

Yeah have the wiseco setup already, just need to get the cylinders to the machine shop to get bored out. Thanks though

[Greenmachine]

Got the rear brake pedal and master cylinder mounted today. Welded two spots on the frame and filed them flat to prep for drilling and tapping for the master cylinder. Cut some 1" tube down to sleeve the stock pivot and welded it in place on the frame. Here's the pics, not the most exciting thing to look at but I think it's pretty clean and will work well.





Still have to cut the lever and extend it a bit to bring it up level with the peg.

[jester63755]

Man Greanmachine, thats looking sweet! It says here u live in Cape? I live in Jackson and I wouldn't turn down an invite to come look at that bike ur building!?!?!?

[Greenmachine]

Started the exhaust tonight got some 2-1 collectors from columbia river mandrel bends and some pre made bends from speedway. Here's some pics