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Old 07-20-2013, 04:54 AM   #1
3legs OP
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Suzuki GT750 resto/sidecar build.

G'day

I had this GT750 for about 8 years and decided it was time to restore it. I've also decided to attach an old DJP sidecar to it. I was going to do a long winded build report like my old XT600 resto but decided I would restore/build to almost completion before putting up a report.

Most of the report will be about the resto because the sidecar build was pretty straight forward (done enough of them over the years).

I decided to use the DJP as it's period correct. Some of you may recognise the sidecar. It was Snayles. I swapped him one of my Ali bodies for the DJP.

Here we go.......

This is what I started with. It's a 1975 Suzuki GT750.



The start of the build.



I will put some more photo's on soon. I just want to make sure they are loading.

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Old 07-20-2013, 04:56 AM   #2
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OOPS. The photo of the bike didn't load. Will try again.

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Old 07-20-2013, 05:15 AM   #3
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That'better. Continuing on. More photos's of the chassis. I won't bore you with details. You can ask questions as I go.













That's enough of the build for now. Now for the resto.

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Old 07-20-2013, 05:47 AM   #4
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I have taken heaps of photo's but will just put up the stage by stage photo's. I won't do a CLANCY and stretch it out



I tried to do everything myself. Got the frame powder coated. I relaced the wheels. First time I've ever done it. It's not as hard as you think. Most of the parts required have come from specialist shops especially from Discount Bike Spares in England. If you need any parts for old Suzuki GT's they are the people to speak to.



The engine was actually in pretty good nick. All I did was put new crank seals in and pistons and rings. Pistons only cost me $100 for the lot from Cruizinimage. Brilliant website if you are looking for cheap engine parts for old Japanese bikes. Not a big range the big ticket items are super cheap.



Engine in frame. I sodablasted the engine cases and painted it in cast aluminium. Not sure if that was the correct colour but looks pretty close to me.



Getting the gear indicator was near impossible (my was missing) and the one I could find was fairly expensive but luckily I also have a GT550 waiting to be restored which also had a gear indicatior which thankfully is the same part. I wanted to make sure it works and it does, for all gears. I restored the gauges. Trying to get the chrome ring that keeps the 2 halves together is impossible short of spending 100$$$ to get them done professionally so I got an engineering friend to lathe some up out of stainless steel and $20 later and all is good.



After getting everything chromed I have got it to the stage where the motor is almost ready to fire up. Will put the radiator on tomorrow. I put the old tank and sidecover just to see how it came out.



Here is the finished sidecar chassis. I blasted the wheel and got the same bloke who polished my engine cases to polish the rim. Came up real nice. All I have to do now is paint the whole thing. I'm going to paint both bike and sidecar body in the original Gypsy Red, a candy colour. I've never tried to paint with a candy colour but will give it a go. If I fail at least I tried (unlike the Aussie cricket team at the moment)

Anyway that's the condensed version of the resto/build. Will post more photo's as I go.

Later

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Old 07-20-2013, 06:07 AM   #5
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Nice work


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Old 07-20-2013, 06:38 AM   #6
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Not sticking with the chambers? Basani are they?

Gauge resto is bloody smicko, 3Legs. That bit in particular
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Old 07-20-2013, 07:50 AM   #7
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I had one of those in the early 80's. Lovely bike. Spat one if it's baffles out riding through Stoke and a following lorry flattened it!
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Old 07-20-2013, 06:47 PM   #8
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Hi Ray. No I'm not keeping the old exhaust. No idea what make it was. It was too loud anyway (not for me but for the cops). It was in bad shape anyway. I tried to get the baffles out of the original exhaust but they are stuck fast but hopefully after getting them dipped for the chroming they will get spat out on the first ride.

Here's the link to Discount Bike Spares if you are looking at restoring an old GT. He has parts for all models eg-750,550 and 380. Also has parts for some GS's.

http://www.discountbikespares.co.uk/

Back to the shed and start preparing the bodywork for painting.

Later

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Old 07-20-2013, 07:43 PM   #9
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Great work 3 legs, I have always liked those GT 750 water bottles and the DJP is a perfect match of the time! Don't know how long the resto has taken but it looks like a heap of work! Again great work
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Old 07-21-2013, 12:00 AM   #10
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2 Smokes

I love those old 2 smoke triples. We also called them stink wheels.But loved their simplicity and in their day they were untouchable (every stroke a power stroke). I had a Suzuki T90 and GT380 in the 70s loved them both
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Old 07-21-2013, 06:43 AM   #11
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Great work

Why does the term ''water buffalo'' come to mind ?
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Old 07-21-2013, 06:10 PM   #12
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Niiice Alex, very nice!

Now, will we see you on it at the Fish Holes in November?

You would definatley win peoples choice with that.
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Old 07-22-2013, 02:07 AM   #13
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Hi Dave, doubt that mate. Besides i'm actually going to try to get to Pooncarie this year (I can hear the groans from Neil shouting yeah right)

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Old 07-22-2013, 07:02 PM   #14
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Quote:
Originally Posted by 3legs View Post
I tried to get the baffles out of the original exhaust but they are stuck fast

3legs
Did you try lots of heat?
Or caustic soda? S'pose that's what the chromers will use.

I've even heard of people dropping some fuel in and attempting to (quickly) burn the carbon off. Not something I'd be attempting, there are braver folk than I.

Pity about the chambers. Just another example of how a triple is the best sounding engine, as long as the pipes are decent.

Where is the auxilliary fuel tank going?
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Old 07-27-2013, 01:39 AM   #15
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It lives, It's alive. There'd be fire in them barrels. Started it up today. Bit rough on idle but smooths out with revs. No smoke whatsoever. Just needs a fine tune and she should be right. Mind you, using 3 month old fuel wouldn't help.

Anyone know what octane fuel to use. I had some 98 ron sitting around so I use that. I think it might be too high. Not sure.

Later

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