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Juvenile Thinker
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Discussion Starter #1
So I picked up a 94 750 this morning that has a bit of a back-story, and a lot of promise. Seller was a young gal whose dad had bought the bike for her as a project, and never got to it. She wanted it gone so she could concentrate on her sailboat. I was happy to oblige. Bike started life as a 94 750. Somewhere along the line the frame acquired a broken rear upper shock mount. A 1992 GSX-R 600 donor bike was then found and the 750 was transplanted to the 600 frame. And that is where I found it. For the paltry sum of $500 I walked away with a running frankenbike 750, all the required paperwork to get it licensed (including the State Patrol inspection paperwork, affidavit of change of ownership, original title, bill of sale, etc.) a spare 600 motor from the donor bike (in unknown condition) a couple sets of plastics, parts for both a 93 and 94 upper fairing, a box of miscellaneous parts (gauge cluster, complete set of rearsets, complete rear brake setup, intake/exhaust cams, 2nd radiator overflow reservoir, couple jars of bolts/nuts/fasteners, upper triple with ignition key cylinder-but no key, and a bunch of other odds and ends) and 2 full sets of saddles to include main and passenger seats and seat cowls.....that's right 2 Seat Cowls! 1 even had the buttrest pad still on it. Plan is to build it up so I have a bike to ride since I can't get my son off the 600 we did last year.








And the piece de resistance
 

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WOW! Those are both OEM seat cowls! The two seat cowls alone are worth almost $500!

You got a REALLY good deal!
 

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Juvenile Thinker
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287 Posts
Discussion Starter #3
Yeah, when I saw the Craigslist ad I sent them like 50 texts asking when can I get there lol. She had no idea what anything was and just wanted it out of the garage, I couldn't get the money out of my wallet fast enough!:frantic

After looking at them they are two pieces, and would be really easy to duplicate. I think my next side project might be just that.
 

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Juvenile Thinker
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287 Posts
Discussion Starter #4
Started tear down this weekend with the help of my son. First issue I found is going to be wiring harness. Lots of broken wires, connectors jury rigged, etc.

Getting the subframe off involved drilling 2 of the 4 allen head bolts that the PO had rounded out. The left side rearset I'm not sure what it came off, same with the rear axle ,looks like the one on my dirtbike


Lower triple is powder coated black, so not sure if it is the original or not. Ended up having to use an extractor to get 3 of the 5 rear disc bolts out, and about half of the front ones. But at least it is down to the frame. Not going to spend anywhere near what Bad_T did on his rebuild, set the bar pretty high there, but do want to take my time and get everything right.
 

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Not going to spend anywhere near what Bad_T did on his rebuild
Ha! Thats what I said when I bought mine non running for $600. Several multiples of the initial price later, I've learned not to make promises I can't keep!

Looks like an awesome project!
 

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Juvenile Thinker
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287 Posts
Discussion Starter #7
Ha! Thats what I said when I bought mine non running for $600. Several multiples of the initial price later, I've learned not to make promises I can't keep!

Looks like an awesome project!
lol, true. The 600 I did I only doubled what I initially spent. First part arrived today, a 2007 GSX-r1000 rear shock to replace the badly worn stocker. I now have three of those old remote reservoir paperweights
 

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I got my non running too for $600. It took $100 to get it running(cdi/carb cleaner). I stop counting at $3000. (includes the $600)
Only thing left to get is a better gas tank and paint job.
 

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Juvenile Thinker
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287 Posts
Discussion Starter #9
Slow going with all the great weather we've had, no time for the shop. Did take some time this weekend to get the motor in and start on the fork rebuilds. Since I was by myself and my floor jack was in use elsewhere had to come up with a way to get the motor in the frame by myself. Found the easiest way was to lay the engine on it's side and set the frame over it, bolt up one side, flip it and bolt up the removeable member, then stand it up and torque everything down...took all of 20 minutes :). In the last pic you can see the next write up I'm working on...coil pack conversion. I got a set of 2007 GSXR COPs that ohm at 1.7 ohms each (3.4 in pair) and some Denso plugs with leads (cheaper than finding a wire loom to cut up). Whole thing was under $30 on ebay. Can't wait to get it wired up and fired up.



 

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Looks great...will be watching closely. :wait
 

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Juvenile Thinker
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287 Posts
Discussion Starter #12
Got a little shop time in this weekend. Front end is together, working on the fairings and supports. The mirror stay is a pain in the ass to find. I have one that is pretty beat up but may be able to straighten it out. Wiring is being gone through to fix some broken and missing bits and prepping the Coil On Plug mod. Waiting on a new rear disc to put the back end back together.


 

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Juvenile Thinker
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287 Posts
Discussion Starter #13
Been awhile since I updated this build. After the rod let go in the 600 and punched a fist sized hole in the case (600 engine woes). Not a lot of progress pics as I was just trying to get at least one bike back on the road. Did do the Stick coil conversion and
SV650 aftermarket levers and have put about 30 miles on it so far. She looks like a bastard stepchild with 3 different color fairing pieces atm, but I figure maybe that will make her less of a theft target :dunno

The wounded little brother in the shop next to his big brother


Nearing completion
 

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Juvenile Thinker
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287 Posts
Discussion Starter #15
Well, I have developed a small coolant leak somewhwere, just can't seem to pinpoint it. It definitely is on the left side of the engine and the back side of the motor (between them motor and carbs. Nothing spewing while it's running but it ends with a wet spot under the bike after 20 mins of riding (enough to get the toes of my boots wet). Checked the fluid level immediately and there was no noticeable drop. Drained the coolant and it is still a nice flourescent green. Drained the oil and no evidence of coolant there. Have seen some folks have issues with leaks around the edges of the head gasket. Next step is to powerwash and dry the motor and then dust it with some talc and see if I can find the leak. Any other ideas?
 

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The thermostat housing is prone to leaks as well. It drips down the engine.

There is a seal around the thermostat and an o-ring that attaches the plastic outlet to the housing. PM me if you need an o-ring, I can mail you one. I have about 10 sitting here with no use.
 

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Hi,

Once, my bike has a leak from one of those metallic elbows in the back side. I repaired it with plumbing solder. Check all the hosing and have in mind that leaks may start from one side but show at another.
 

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Juvenile Thinker
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287 Posts
Discussion Starter #18
Thanks Sabba, thermostat was one of the first culprits I had in mind after searching the forums. Wasn't able to detect any leaks there (I actually put a lyer of toilet paper below the housing and hoses on top of the motor and ran it for 15 mins and it was bone dry up top. Next is to work further down. I'll take a good look at the riser pipe Ktulu. I know the clamps are all tight there, but could be a pinhole there I suppose. I'll try and get some pics up later, but sidetracked this morning and picked up a new dirt bike project...I need a bigger shop :lol
 

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