New to me SRAD 750

Update as of April 12th. I received a few parts but still waiting on delivery of others. Some progress and a few problems and surprises along the way.

I received the fuel pump rebuild kit I ordered. I installed the new pump and tested it and it works. The fuel strainer that came with the kit is unusable because it is too bid and won't fit in the fuel pump assembly housing - so I had to re-use old strainer. After reassembling the fuel pump, I installed it in the fuel tank with the old gasket because the new gasket I ordered has not arrived yet. I used gas resistant gasket maker on the gasket to try to seal it. It didn't work - fuel leaked within a few hours. I'll just have to wait until the new gasket is delivered. Also, when installing the fuel pump on the tank, I realized that one of the 8 threaded holes on the tank was stripped. I tried running a tap to clean up the threads but it didn't work. Looking through my bucket full of spare bolts and screws, I happen to find a cap screw the next size up. Using the next size tap, I carefully tapped new threads in the tank for this bigger cap screw - all good now. Just waiting for the new gasket to reinstall fuel pump and reinstall tank on the bike.

I am still waiting for the caliper rebuild kits to arrive as well. In the mean time, I started disassembling the front calipers. Anticipating that some of the caliper mounting bolts would be seized and difficult to remove, I soaked them in liquid penetrant overnight. The next morning, I started removing the caliper mounting bolts. Sure enough, one of them on each front caliper was seized in place and would not move. Tried cold, heat (propane torch), hitting with hammer, no luck. I drilled the bolt head and tried 2 bolt extractors I had at home - both slipped and could not extract the bolts. The last extractor I tried, the rectangular fluted type like the picture below, worked and I was able to remove these two remaining bolts. Now able to split the calipers in half, I removed the pistons and seals and started cleaning the old brake fluid and corrosion. The calipers were very dirty; they've likely never been serviced. After several hours of cleaning with several small brushes and some fine emery, I got the calipers looking really good. And I found some grade 12.9 socket head bolts of the same thread and length at my local auto parts store, so I don't need to replace the two bolts that I wrecked with Suzuki OEM bolts that are very expensive. Now I just need the caliper rebuild kits and new pads to arrive and I can put these front brakes back together.

Slow progress, but progress nonetheless.

i've got a FI 750 srad I need to do the same to, runs like a top, chassis and swinger is trashed, wanna powder coat them, go over the bike, need to move the 600 to have room tho, craigs wants a credit card to post for sale ads anymore, $5 which isn't an issue but I don't want them having any of that data so they can sell it to whoever so i have no way of listing it really, it really needs to be ridden more than I do, gas is just wretched anymore for sitting carbys, starting a lil funky cuz of... fast idle stopped working? I better burn that gas out and fill with fresh e free.. hale those 5 cans I bought i only used 2 of em Ibet they are ripe about now, burn it in my car... hehe, she burns anything... the beauty of FI, if a pump can push it to an injector and an injector can let it thru generally it burns.. carbs are so darn sensitive to the slightest build up or corrosion, ride it every day it wont build up, really like to see it go to someone who needs a good commuter, its jetted smaller for a lil better MPG and does well if not hammered on, on 3 gallons I can go 135 miles with her.. not bad really and it does have that hit up top still...

Update as of May 21. I finally received my OEM fuel pump gasket, installed it and it sealed well. Caliper rebuild kits and pads arrived for front brakes, installed, bled, working good now. Still a little more spongy that I like, will rebleed again. Installed new LED flashers to replace the ones on the bike that were crap. Cleaned up some paint scuffs and holes in the fairings as well. Installed the gas tank, said a prayer and attempted to start the bike. It did not start. Sprayed starting fluid in the airbox and got a couple of pops when I was trying to start it, but it still wouldn't go. I then opened up the throttle as I was starting it and it fired right up! It wouldn't stay running unless I kept opening the throttle. Once it got hot, it ran better. I adjusted the idle speed (was much too low) and now the bike starts up fine just with the fast idle lever, don't have to manually open the throttle. I let the bike warm up to over 100 C, could not detect any fluid leaks and the fan came on once I hit over 100 C. I adjusted the clutch free play as well.

At this time, there are two problems that I know of. The first problem is battery is not getting charged when the bike is running - only have 12.8 V at battery when running. I tested the R/R and it failed. Will have to replace it. The stator is pumping out 55-60 Volts AC at 5000 rpm, which is lower then it should be but hopefully good enough. Other problem is the neutral light is not coming on and the bike will not run in neutral unless the kick stand is up. I'll start new posts for advice on these two issues.