Suzuki GT750 Neuvo Retro Cafe Racer

[Rassie]

I have made some real progress and apologies upfront for no pictures but I will make up for it this weekend. I finished the paint on the motor and got it back in the frame.

Also got the expansion chambers on and fabbed up some mounts for it.

Also had to make some different mounting plates for the rear sets since the expansion chambers kick up in the rear more than anticipated.

Fitted the standard chain and the alignment is spot on, however clearance is tight about 2mm at the tire and about 2mm at the mount for the chain guard. Me thinks an o-ring chain may not work here.

And finally modded the side/kick stand to clear the exhausts. Pictures to follow.

Here are some pics of some of the things done.

[RING_DING]

Looking good Rassie! Won't be long now and we'll be able to line up our three Kettles and start a new thread on here called "Kettle - the evolution of the species"

[Suzukidave]

Fitted the standard chain and the alignment is spot on, however clearance is tight about 2mm at the tire

The project is coming along so nice ... Yeah , like i posted before .. i have been down this path and the 160 tire was the widest safe tire to slip on to use a o or x ring chain and not get rubbing on the tire . And you may need to look into a slider to keep the chain off the shifter rod and the top of the swingarm pivot . TZ375 's web site http://www.pinkpossum.com/GT750/phattrakka/part4.htm" onclick="window.open(this.href);return false;

[Rassie]

Fitted the standard chain and the alignment is spot on, however clearance is tight about 2mm at the tire

The project is coming along so nice ... Yeah , like i posted before .. i have been down this path and the 160 tire was the widest safe tire to slip on to use a o or x ring chain and not get rubbing on the tire . And you may need to look into a slider to keep the chain off the shifter rod and the top of the swingarm pivot . TZ375 's web site http://www.pinkpossum.com/GT750/phattrakka/part4.htm" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false;

I like those solutions. I may just as well do them both while I am at it. I will look at it this evening and see if it is needed. Thanks for the link and heads up.

[Rassie]

Looking good Rassie! Won't be long now and we'll be able to line up our three Kettles and start a new thread on here called "Kettle - the evolution of the species"

Yes I am getting pretty close and looking forward to that. It is actually a lot more advanced than posted here just have nit had a chance to take pictures.

[Rassie]

Got some more stuff done. Took off the clutch cover to see what it looks like inside there and also replace the kick start seal. Looking pretty nice, this motor is very clean inside. I am starting to think it was a great idea not to rebuild it [:D]

Shot of the clutch..


and after buttoning the whole thing up again with new SS bolts and fresh gasket and some polishing.


And the other side also after some polishing.


Full right side view with the chambers on, the hangers are off to be powder coated.


Full left side view.


Rear view and some shots from the front.






Next is the Electronic Ignition and some left over wiring, then the radiator will go on. The rad was a bitch to get clean. I must have washed it out 15 times with 3 different solutions (CLR, Evaporust, Purple Power) but I did manage to get it very clean and a lot of crap did come out of it.

Then the carburetors have to be stripped and cleaned and re-jetted for the chambers. Hopefully all of this will be done before Xmas. 2013 is when I want to spend time on the paintwork.

[Suzukidave]

I checked out your site http://www.mybikeproject.com" onclick="window.open(this.href);return false; and see you have have had a bunch of very nice custom bikes you have made but i bet you are going to love the sound and feel of this big 2 stroke its looking real good .

[Rassie]

I checked out your site http://www.mybikeproject.com" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false; and see you have have had a bunch of very nice custom bikes you have made but i bet you are going to love the sound and feel of this big 2 stroke its looking real good .

Yes I have been at it for a while but my website is way outdated. Hoping to update it with 4 other projects I have done in the mean time over the holidays. I have had a GT750 before, 3 to be exact. But this one will top them all. Back in the late 70's and early 80's when I owned the other ones there was not much you could do about either brakes or handling. This one will stop and hopefully handle well.

[tz375]

It's looking sharp. You have probably not finished fine tuning the rear sets, but the shift linkage will cause issues as it is. Try to get the arm on the motor and the arm on the shift lever parallel and perpendicular to the lever. Acute or obtuse angles can make it very difficult to shift in one direction or both

[Rassie]

It's looking sharp. You have probably not finished fine tuning the rear sets, but the shift linkage will cause issues as it is. Try to get the arm on the motor and the arm on the shift lever parallel and perpendicular to the lever. Acute or obtuse angles can make it very difficult to shift in one direction or both

Copy that, the new longer shifter rod from a GSXR600 came in the mail this afternoon. Will work on getting it fitted over the weekend and make things perfect.

[Suzukidave]

Hi Rassie , what ya been up to

[Rassie]

Oh just working on the mundane stuff that has been over posted on the forum, like checking the valves in the octopus, checking the oil pump function, mounting the radiator, fitting the electronic ignition and cleaning the carbs. I will post some pictures over the weekend.

[Rassie]

So I have not been posting much due to the unexciting work I was doing. Stuff like installing the Electronic Ignition, polishing the side covers, bleeding the 2 stroke oiling system and so on. Nothing that actually requires any fabrication work. Also stripped and cleaned the carbs, new jets arrived today so I am ready to put those back on. Waiting for the new K&N filters and as soon as they show up there is no reason why I cannot fire the bike up. Exciting idea that, but more later in the week. So the last couple of days I was struggling to figure out how to cut the holes in the fairing for the headlights. They have to protrude through sections on the fairing that is not flat so the holes will have to be kinda oval. Anyway after some brain power enhancing malted beverages the ideas started flowing and I came up with the idea pictured below. Basically it is two round plastic lids bolted to a bracket that is then bolted to the center points on the fairing centering the holes. Then you make a hole for the pen or Sharpy to go through and you make little dots as you go around and hey presto perfectly aligned holes. Also have some shots of the cleaned carbs..









Clean carbs...





Polished the tops.

[CJF]

Damn good idea on the template for the holes. I have been trying to figure out how o do the same thing for my fairing. Think I'll copy your idea since it worked so well! Thanks for he tip. Lookin forward o seeing you bike finished.

[Rassie]

I am about ready to install the new jets on my bike, but I am getting conflicting information regarding jetting.

The stock main jets are Cyl 1 = 110, Cyl 2 = 107.5, Cyl 3 = 110 (according to my Clymer manual) pilots are 45's in all three . When I got the bike it had El Cheapo K&N style cone filters on it (can be seen in the earlier pictures of the bike in this thread). Also all the baffles were removed. It was running pretty well and had great low and top end power. It did overheat after riding about 6 mile give or take, but I think it was due to the radiator being partially blocked or a timing issue. I replaced the water pump and cleaned out all the crud and corrosion in the motor and radiator. So that problem should be eliminated. I also installed the Accent electronic ignition system so that problem should also be eliminated. Reason I am mentioning all of this is that it could have been running lean as well, which would have helped along the overheating issue.

Anyway this is the state I got it in:

1. Stock jets, (Cyl 1 = 110, Cyl 2 = 107.5, Cyl 3 = 110 and pilots 45's all round)
2. Needles on the lowest setting, (Not sure where they are in stock form but assume the needles have been lifted from stock).
3. Cone filters,
4. Baffles removed.

Now I have added the Jemco pipes and have purchased better K&N filters like these below.



The guy from Jemco suggested going 2 to 3 sizes larger than standard on the jetting. You could read that 2 ways.

1. Go from 110 to 112.5 (2.5 actual sizes up) or
2. go from 110 to 115 (2 available sizes up)

I did not think to clarify at the time I was talking to him.

Anyway I purchased 112.5's, 115's as well as 117.5's so have these sizes to play with right now. Thinking of buying 120's as well, just in case.

Questions:

1. So my first question is, do I start with the 112.5's or 115's as the first step up. I am thinking if I go to 115's and it runs poorly then I would wonder, hhmmm would the 112.5's have been better.

2. My second question is, is there anyone else here running Jemco's who can provide information as to what works best for them and their particular setup.

3. Third question is regarding the center cylinder, since I have gone to Electronic ignition, (assuming the points are set up to retard timing on the center cylinder somewhat to avoid overheating and hence the 107.5 smaller jet size) should I not use the same size jets for all 3 cylinders?

Any help or feedback will be great.