Goodbye Green Machine

by Ryan on Nov.22, 2009, under

I'm late posting this but on Tuesday the Suzuki went to a new home. I took pictures of it Sunday after dinner and posted them Monday on KSL classifieds. A few people inquired of the bike and one made an offer. I've already been chewed out by everyone for letting it go so cheap. I only got 600.00 out of it and probably should have tried selling it other places as well. But, the damage is done and after meeting Chris, the buyer, I feel like it went to a good home.

Here is a little photo montage to remember it by:












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How to Fix a Clutch

by Ryan on Nov.22, 2009, under

Step 1: Learn how to read. Or at least how to look at pictures.

I was not only missing one of the clutch rings from the set but I didn't have the clutch bolted to the bike. It was spinning free and had no way of engaging. After draining the oil, opening the case adjusting the clutch(to include adding missing parts), setting the timing, closing the case and adjusting the points, TWICE, we got the clutch to engage the way we wanted it to. Brant took the maiden voyage and shortly after he returned I took the bike out.

Our first discovery was that it wasn't firing on the right cylinder. It may have been a result of the petcock not putting any fuel to that carb. After we each rode the bike once, Trev included, we found the right selection for the petcock valve and the second time Brant took the bike he had blue smoke coming out of all four pipes.

It seemed like that 3rd cylinder was either engaging at about 6500-7000 rpm or that is the bikes power band because once the motor hit that area it would really open up. I'll bet the bike would really scream if the carbs were tuned and firing on all cylinders.

I need to fix the turn signals. They come on but do not blink. And the rear brakes need replacing. The front brakes need adjusting at the least and maybe replacing as well.

Now that I've rode the bike I can let it go to a nice new home without any regrets.
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IT'S ALIVE!!!

by Ryan on Nov.22, 2009, under

Dr. Frankenstein's green monster arose from the dead today. Like everything else with this project we had to do it twice. I forgot to line up the timing marks inside the crank case the first time we put it together so Trev drained the oil and we started over again. The second time was the charm. After a little carb cleaner in the pistons, for a prime, the green monster came to life. It sounds like a chain saw but it runs hard.

Here is the bad news. The clutch still won't engage the motor. On the center stand it will spin but the weight of the bike is enough to stop it. I may throw in the towel and sell it as is now that Trev has a bike.
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Timing Plate

by Ryan on Nov.22, 2009, under

As always, Dad came through with just the fix I need. Today he had someone at the school weld a washer on to the timing plate with the tig. I'll have to cut it down a little and grind it smooth but that will be easy with my new pneumatic angle grinder. Once I get that little piece smoothed out we can put it back together.

I do want to make some internal clutch adjustments before closing up the cover again.
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Out with the old.

by Ryan on Nov.22, 2009, under

And in with the new!

I will still have to have Dad weld up the little timing plate but I did also order a pin. I need to do a little looking into how to properly assemble a clutch because I think that right now it is permanently engaged. With those two problems fixed it should be good to go. (Knock on wood)
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New Timing Gear

by Ryan on Nov.22, 2009, under

I finally ordered a new gear for the bike. I also ordered the pin that is missing but wasn't able to order the timing plate so we'll have to weld it back together. Out the door it was $45.00. With a $30.00 gasket kit and $20.00 for a battery, maybe that much again in oil, carb cleaner and such, I figure that I'm in it a little over $100.00.

I told Rachel already that as soon as it is running I'll put it up for sale. I'll ride it around until it sells of course. I pulled up the NADA guide values for the bike and posted them below. I would like your input on what would be a reasonable asking price for the bike since you've all seen it.

Excellent: $2,875
Very Good: $1,875
Good: $1,375
Fair: $500
Poor: N/A

Value Explanations
Prices shown are retail consumer values and to be considered as selling prices.
Excellent — A very correct and original (even if it shows the patina of its age) or an exceptionally well-restored motorcycle. This category is reserved for concours or show quality machines only, in which everything on the machine is fully functional and operates as new. All equipment is original, new old stock (NOS) factory replacements or uses of excellent quality reproductions parts.

*Over restored machines (custom paint, over polishing or chroming) do not fit in this category as those activities detracts from the originality of the machine.
Very Good — A very presentable, original motorcycle that may show signs of minimal wear or a fully (mechanically and cosmetically) restored motorcycle that does not meet concours standards, perhaps due to the age of the restoration or overall quality. All systems are fully operational and the machine is not in need of repairs.

*Most non-professionally restored done correctly would fit in this category.
Good — A machine in nice condition for its age that may need some minor mechanical attention and cosmetic rejuvenation to be a “good rider”. Bikes in this category generally look used but are still usable, whether it is for dirt or street use. Frames should be straight and unaltered.

*The replacement of tires, tubes, brakes, chain, sprockets, air filters and other minor parts should be anticipated.
Fair — A motorcycle that is worthy core for restoration. This would exclude machines with major frame and engine modifications that would be cost prohibitive to return to original specifications. All mechanical and cosmetic aspects of the machine will need attention in the restoration process. This is a complete motorcycle with most if not all of its body, engine and suspension components intact, albeit in poor condition.

*Motorcycles with missing engines or major components are commonly referred to as “parts bikes” and are not covered in this category.
Poor — Used for Harley-Davidson and Indian motorcycles only. A poor condition motorcycle has been used and abused and needs major mechanical and/or sheet metal work. It may or may not run. Alterations are evident to frame or sheet metal. Motorcycle is missing or has incorrect parts, i.e. fenders, tank, seat, mechanics, installed. To some individuals this is a “project or parts bike” at best. A #5 motorcycle is one best left to the professional for restoration.
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Busted Timing Gear

by Ryan on Nov.22, 2009, under

We finally got that nylon gear off today. It was very broken. The gear itself is nylon and is mounted to a metal bushing. My first thought was that we could have a new gear machined but that isn't going to be the case. So the search is on for 1973 plastic parts.
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Times up

by Ryan on Nov.22, 2009, under

Ya so what. We didn't make the deadline. As it turns out the timing gear is broken and the cam won't stay in place. The last time I adjusted it the bike cranked right up and ran like a banshee for 15 seconds or so before it spun loose. A little timing work and we should be money.
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Timing woes

by Ryan on Nov.22, 2009, under

That dirty bugger. We got it running for about a minute and I think that it spun itself out of time as I had forgotten to tighten down the timing plate. Now we can't seem to get the timing right. We synchronized the carbs and the oil pump. Bled the oil pump and adjusted the carbs according to the manual. Put a fresh charge on the battery and still no dice.

To make matters worse, it doesn't act like it is engaging in gear. The shifter is shifting but the transmission doesn't seem to catch the motor. I'm not sure if it is a clutch adjustment or something worse.

On top of all of that, TIME IS RUNNING OUT!
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Mounted.....YESS!!!

by T-Dogg on Nov.22, 2009, under



Last night dad, ryan, and i, got lots of time to work on the bike. we started off with mounting it, then we moved to the carbs, and the air filter intake, whatever. tomorrow we will flush the tank and place the rest of the accessories on it. the bike is coming along better than i thought, but now we need to find a battery, the correct battery for the bike is pricey so a replacement will have to do. just a little more work and this baby is gonna be running.
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1 step out of the way!

by T-Dogg on Nov.22, 2009, under


Finally we had time to get some work done with ry being gone all the time, last night we finished with the clutch. took some time but we figured it out, and we are making some progress, very shocking. but the engine is in a lot less pieces and looks a lot better....just a little more time and we should have this baby up and running.
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One step closer?

by Ryan on Nov.22, 2009, under

ARRGH, this is getting frustrating. I wish I had more then one hour at a time to work on this little project. Trev did a good job finishing the gauge assembly. The welding hood shields made great replacement glass for the speedo and tach. We started lining up bolts with covers and it looks like it is all there. A few of the screw heads are stripped out and will probably have to be replaced. We set the alternator in place and will soon be ready to replace the clutch and the right side covers.
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Clean Carbs....Check

by Ryan on Nov.22, 2009, under

Well check that one off the list. They looked like they were full of caramel but after copious amounts of carb cleaner they look great. Thanks Trev and Brant for working on them. If the gasket kit ever gets here will be in good shape.
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The Clock is Ticking

by Ryan on Nov.22, 2009, under

Good thing I have a long weekend coming up. The gasket kit should be here soon. In the mean time the carbs need to be gone though and a little more polishing up of the block. We should inventory the bolts for the covers. Hopefully we have everything and can get down to business. Shouldn't take too long if we have what we need. Just because I said that it will be a disaster. Way to go Ryan.
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Cleaning up nicely

by Ryan on Nov.22, 2009, under

I spent an hour or so just cleaning up parts with Dad tonight. Most of the rust cleaned up really easily. The oxidation on the aluminum however is pitted a little deeper. I figure that it is cosmetic anyway and my concern is making it run again. The cylinders have really freed up. The crank can be hand turned now. Things are coming along nicely.
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Gasket Kit

by Ryan on Nov.22, 2009, under


I found a complete gasket kit from partsnmore.com for $30. I'll get it ordered but I wont be able to work on it for a few weeks. I'm also going to pick up some more penetrating oil and wire brushes.
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Good News: Part 1

by Ryan on Nov.22, 2009, under

Went out today and sprayed a little penetrating oil in the cylinders. We next found a socket and ratchet and gave the crank shaft a little turn. Ready for the good part? That baby turned with very little effort.

We separated some of the parts into groups, plastics, engine covers, clutch parts, gaskets, mystery parts and coolwhip containers full of bolts and springs. I think that we are well on our way to having this lil baby licked.

We also sprayed some penetrating oil on everything that was rusty. We'll let it sit over night and try to get it cleaned up soon.
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The Project

by T-Dogg on Nov.22, 2009, under


So to start things off we have a 1973 Suzuki GT380. The bike needs a lot off work, but we have the manual, hopefully most of the parts, and two big hearts that would love to see her screaming down the street.
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Our Only Hope for Success

by Ryan on Nov.22, 2009, under

Last night after a discussion I set out once again to find the missing repair manual for the Suzuki. After an hour of looking in all the places we had already looked, I went back to the bookshelf where the book was kept. I proceeded to pull books off the shelf to see if by any chance the manual was stuck behind them. As it turns out one of the girls paper back books had been placed on the self just so as to hide the manual inside of it. Mystery solved! Now time for the work to begin.
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