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That bike is absolutely gorgeous.  I have rebuilt a number of GT750s stock, resto-mod and full on specials and none were as pristine as that one.

Knowing what mine cost to rebuild, I don't want to think about the cost of that one.

Here's an A model (76) I did a few years ago.  http://pinkpossum.com/GT750/images/longgrass.jpg

and the Phat Trakka on a Sunday afternoon ride.  I can't recall if it's a 74 (L) or a 75 (M) but it's lightly modified  http://pinkpossum.com/GT750/phattrakka2/PTdrag.htm

Nice work on that M (75). It is a really nice resto.

Thanks for the nice words. I love the color of you bike, really nice.

Cheers,

Sky

After a few setbacks with piston issues, etc, I finally have the kettle where it is done. It starts, idles and revs fine. The clutch, brakes, suspension all work great. I will do a little fine tuning here and there and correct some small things but it came out a lot better than I expected. Everything on the bike works as it should and so far has presented no issues. I will follow a strict break-in procedure and re-torque the head, etc. I have some break-in oil and will change that out in due time.


For now, it's time to take a little break before I get started on the 74 kettle I just acquired.


Cheers,

Sky

*Video:

https://www.youtube.com/watch?v=3BkD6XCcNE0&feature=youtu.be

*Pix with tank, seat and side covers on is mock-up only.


The engine is in and I've got to say it was not easy but most of use have been through that and can relate. The good news is that after a rough hook-up of the electrical system, there is good spark to all 3 cylinders. The break-in oil is in and no leaks. The kick starter is on and it kicks through with ease. Rear chain is on as well as the chain guard. The Delkavic exhaust system is in place after a bit of fiddle this and that and looks good. I tried to use the OEM pipes but the right outside one is damaged and so far two different metal shops say it cannot be fixed. I will still try to get it fixed proper. The ones on Ebay are all of not reusable quality but for now, the Delkavics will do.

The carbs as well as the water system get hooked up; next, (*Throttle cable on first!) The clocks are being done by myself and should be done soon. It is a very "Sanitary construction."

I have spark!!!


Sky

well its at a point where the bike looks somewhat like a bike, two wheels, etc. The forks have all new seals, etc, the front brakes have all new rebuild bits, the wheels have all new bearings and spokes. New shoes for the rear brake, all new fasteners for the center stand, all new chrome fenders, new trued and skimmed discs up front. There is more I am sure but the wiring is next? The parts vendor sent me the wrong bendy washers for the rear hub, have to wait for them. ordered new emblems for the calipers, still waiting on the cylinders.

Curios note. I posted a while back the internal oil pump gear had some serious half moon stress marks on the teeth. I replaced that and the worm gear on the kick start shaft and thinking the oil pump must have too much resistance. Well I had turned the oil pump shaft with a tiny Philips head screwdriver and it seemed to turn but was difficult. I set it aside and got back to it the other day and it would not turn. Opened it up and found bits of metal inside. To the trash bin it went. (*I never installed it on my engine.) I found a perfectly good used one on Ebay and tested it and it works fine. I can't imagine the horror if I would have tried to stay with the first suspect pump.


More to come,

Sky

Getting the old brake caliper piston out:m "Pop goes the weasel!" :

https://www.youtube.com/watch?v=FfeRA4f_cT0&feature=youtu.be


















Rear axle before:


After sanding, re-zinc, polish:

Just doing some more work:

Oli tank. What a mess!



done



Replacing the electrical fasteners. The PO had some twisted wire around a 20 amp blade fuse and scotch tape!







Side cases fitted with new decals and logos





Just waiting on the barrels and head to get back and the engine is done

I had to wait on the oil pump drive gear as well as the shim that goes with it. The PO left out some critical things in this engine and it amazes me what people think will work when rebuilding the things. No worries, press on, keep calm. The case halves went together without a hitch. All bolts re-zinced and torqued up, (Yes I included the little green "O"ring for the water system.) All the kick start bits are in and works perfect. All new seals throughout.  The clutch went in with new springs because the old ones were under spec. New clutch plates as well. Some people say to soak the fiber clutch disks overnight in oil before mounting them. I have never done this and never had a problem in the past. I always motor the engine and use assembly lube in other areas before starting it up for the first time. Got the oil lines in and primed as well. Starter clutch is on and just waiting on OEM lock washer to nip it up. I had to buy the plastic gear from Japan. All the used ones had cracks like the one I took out of my engine. It will be here when it gets here. Rebuilt, re-zinced, repainted the seat lock and water tank cover hinge as well. Did some clean-up on the front brake line holders as well.


Lots more to come.


Sky











New springs:

Old springs:

So, I was ready to seal the two main case halves and doing an inspection of the components and I noticed the oil pump drive gear worn and about to fail. Grrrr! Oh well. I found a really good used one on flea bay for about 19 quid.  A really good price. Will be here soon. I got back some bits from the polishers and the wheels from the chrome shop. They all look first class. I went to my local big motorcycle shop and explained the fresh chrome OEM rims that needed special attention. I have had these guys do many tire mounting and never an issue. Well, you guessed it. They scratched the rear wheel! So, it's off with the new spokes, back to the queue at the chrome shop. Unbelievable!

Doing some more in-hose re-zincing and such. More parts coming from Japan, Canada and England. More to come.

Old drive gear                                                           
.           

New/used drive gear



Before re-zinc                                                             
           


After



Polished aluminum bits


Chromed wheels with new bearings & spokes






Rear wheel with scratch from tire mounting machine.

I installed the battery box with all new fittings, rubber mounts and pad, etc. Looks great. I polished the stainless steel rear grab bar and got the gas tank and side covers back from paint. The OEM emblems will have to be redone before I mount them back open the tank. Any suggestions to the correct fasteners for the emblems?

The wheels will be back from the chrome shop with new spokes this Wednesday as well as all the side cases and bits from the polish shop. The rest of the chrome to follow. The engine is ready to have the case halves joined but I am waiting on a transmission oil plate from flea bay. I did break down and bought the Delkevic pipes as one of my OEM pipes was too far gone to repair and the selection on flea bay is dismal as well. More to come.


Sky






 

 

Seat done. The wrinkles will disappear after it cools from steaming. The hardest part was the plastic-chrome trim. The pan was in good condition and the media blasting & powder coating made it better than new.

So much more to go... :)



.




Steamer,
(yes, that is my Norton in the house.)














*All re-zincing done in-house

Tranny & swing arm & shocks are all in...

I'll prolly have to do that except a descent set costs $1500.

8)

So the cleaning and refurb of some electrical components have been done. The new high gloss PVC sleeving is a great product and OEM as well. Patience is key here.

Front discs, media blasted, high temp painted, sent to TrueDisc https://truedisk.net

for resurfacing....Done

Wheels and hubs sent to Restocycles for complete rework. https://www.restocycle.com/japanese-mot ... estoration

Data plate.....Done.

Muffler bosses, reamed.....Done.

Wire harness, (New) mostly marked.

Triple clamp ball bearing races, extra powder coat removed.

Swing arm; reamed to correctness.

Water plug on front; acid washed, wire wheeled, zinc plated....Done.

Finished all head bolts and washers, found new O rings....Done.

Ordered aftermarket shocks, (GT550, GT750 TEC short cover type Chrome shocks)...Done.

SRIS valves cleaned and 2 of three work, (Soaking sticky one in penetrating oil.). Done.

Now the exhaust quandary. The pipes are OEM and the outside right has two major dents from the PO. I took the pipe to a metal fabricator today and he said he would have to split the seam, fix the dents, etc. Cost would be a lot, (800-1000 USD. 675-852 quid.) The pipes would all have to be re-chromed and new hardware. All in it would cost more than getting a new Delkevic complete system, ($1350 USD / 1100 quid.)
https://delkevic.com/full-chrome-exhaus ... 1975-1977/

The cost of restoring the OEM pipes would be almost double that. Using the method of using an ebay blow out tool would not completely fix the 2 large dents. Opinions, advice?

Ebay device:













So those metal tabs that are part of the frame came with worn out rubber sleeves and had to be removed prior to powder coating. Top tip: Use shrink tubing to replace rubber sleeve thingy:





Sent the 2nd set of jugs and head for vapor blasting. Came back spotless! The brightwork has been sent out for re-chroming, (24 pc.) the side cases are being polished. Just getting the last of my parts in. many, many orders for SGP from Partzillia. Keeping it as close to OEM as possible. Fettling with some of the wiring switches, cleaning and re-sleaving with new high gloss black PVC fro Vintage connections, http://www.vintageconnections.com

Got the discs sprayed black in center and now they are back from Truedisc LLC, https://truedisk.net

Media blasted and painted some switches and the airbox.

Fitted the gear selector, all parts for the swing arm go in tomorrow, (Hopefully.) Using the ceramic bushings.

Fettling with all sorts of parts.


More to come...









































Dig the new zerc fitting:

So, the cases have been gone over tip to tail with many blow jobs for FOD. They are clean, clean, clean. The new water pump went in and the locating screw is set. It just needed a slight tap with a deep socket to set it in place. New bearing and such, so fine. I was going to drill a hole in the shaft on the outside portion of the case if I needed to remove it without splitting the cases. But, I just couldn't do it to a brand new pump. It was oiled before it went in and the impeller vs case clearance checked before the waterproof sealant and gasket went on. I could have used the old bolts but the were in such bad shape I opted for new Allen bolts torqued to 9 LBS. The aluminum water case pump cover was cleaned inside and out and the old gasket gunk gone and a perfect dead flat surface for the install.


The crank went in with our a hitch. All the bearings set in the pins, the "C" locater in and all new seals aligned. Everything triple checked for proper install. The gear change and transmission are next. Stay tuned.


Sky

First of many batches of bit. *Many more to come.





I had the powder coating done on all the bits that need it. Yes, paint is original but the powder coat will last longer. I am using all SGP (Suzuki Genuine Parts) from Paratzilla https://www.partzilla.com here in the states. It has a good supply of OEM / SGP and they keep arriving by the box full. The crank should be back any day now. The cylinders I opted to not have the off center bored ones repaired, (Too bad, they were vapor blasted and that reveled the off center bore.) I have procured a healthy set of cylinders , head and new pistons that were all machined by a vintage motorcycle shop here in the states. I will have them this week. Work progresses at a steady pace and the "Build" portion is underway. Slow and steady wins the race!


Sky


Before any media blasting:
*Typical all over