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2004 GSXR 600, 1992 GSXR 750, 1983 XN85 Turbo & some Euro bikes
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Discussion Starter · #1 ·
I happened to have a 1992 750 in my garage that I haven’t ridden in 20 years. It’s been the subject of several aborted projects over the years.

Now if you’re reading this and thinking “exactly how does one just happen to have an oil boiler 750?” read on.

Many years ago I was stationed at Tyndall AIr Force Base, just outside Panama City, Florida. Across the street from the apartment complex where I lived, another military guy had a 1992 GSXR 600. He and I wound up meeting as we were the only Sportbike riders on our street.

He had a buddy who’d just crashed his 1992 750. He introduced me, and we worked out a deal for the bike. The forks were banana shaped and the front wheel had been pushed back into the oil cooler. Half the body work was smashed or missing.

A buddy of mine trucked it over to my apartment where it basically sat under a cover until I moved here to California. I replaced the forks with a set off of a 1995 750. Had a steering stem machined and replaced the steering head bearings.

With the front end back together, I repaired the upper and replaced the lower with a one piece Airtech lower. I found a carbon front fender from Lockhart-Phillips on clearance and that pretty much completed the body.

After that, I got a new left side engine cover, an aftermarket steering damper and lastly, fixed the huge dent in the left side of the tank. I got rid of the pink graphics at that time and got the tank lined before painting it.

Lastly, now that the engine ran and I could actually ride the bike, I added a stage 3 jet kit from Factory Pro (they’re sorta local) and UNI foam filter pods, and then a 5 degree V&H ignition advance. The bike came with a D&D slip on with the factory header.

I rode it in that configuration for a number of years. From around 1997 until 2001 when I was hit on the freeway by an inattentive college kid in a (wait for it)…….a Volvo. (Our UK members will understand the joke) I fixed the majority of the damage but life took a turn about then.

That is how I just happened to have a 1992 750 in my garage.

So there have been several attempts to restore the old GSXR to riding condition but none have ever been seen through to successful completion.

As a consequence of that turn in life, the old oil boiler sat in my garage for a decade. I actually started on it as project with my youngest son in 2012….but he lost interest so, I did too.

I started again in 2014 but again life took another turn, work on my degree displaced the project so it was again shuffled to a corner of the garage.

A couple of months back, I finally moved the old GSXR onto my bike bench to prep for a renewed effort on this project.

I already have a massive project in a 1993 Ducati 900SS that I am in the middle of but the old GSXR is next up. To that end, tonight I scored a second, though damaged tank for $150 on eBay.
Automotive design Helmet Postal scale Font Automotive lighting

No time like the present to resume collecting the parts that will be needed to return the bike not just to riding condition but to make it a resto-mod of similar vintage that isn’t just plain black like it currently sits.

Consider this just a teaser….it’ll be some time before I’m done with the 900SS
 

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2004 GSXR 600, 1992 GSXR 750, 1983 XN85 Turbo & some Euro bikes
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410 Posts
Discussion Starter · #3 ·
I’m afraid there isn’t much more to share, at least on my phone there isn’t. Lemme see what is on my online and I add the few pics that are. Gotta tell you ahead of time, none of them really give any idea where the project is headed, only where it’s been.
 

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2004 GSXR 600, 1992 GSXR 750, 1983 XN85 Turbo & some Euro bikes
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410 Posts
Discussion Starter · #6 ·
Agreed. Which is why when I bought it, all the pink/blue/pale purple was removed. I peeled off all the decals with a heat gun and a razor blade, leaving only the yellow “R” and white-ish GSX on the tail.

Everything else came off. The pink/blue on the tank was obviously the worst of it as those were paint rather than decal. still, that was stripped away and after fixing the giant dent in the left side of the tank, I painted it Suzuki Pearl novelty black.

It has had that paint job ever since. Gonna change that in the not too distant future….once my Ducati project is complete
 

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1995 GSX-R 750
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Odd that the tank stripes were painted, and non of the rest. My '95 is/was all decals. Getting them off for paint prep has been a challenge. She's coming along though. Should get some more done this weekend. Supposed to be in the 70's on Saturday!
 

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Discussion Starter · #8 · (Edited)
I’m hoping for the same for my Ducati project. I’m at one of those weird crossroads where all forward progress pretty much hinges on one part getting done.

I need to get the tank completed so I can reassemble it and test mount it so I can route wires and hoses correctly. Then get some fuel in it so I can start it and get the carbs rough tuned. Once I get that far, the rest is all down hill.

Remaining body work has to get painted. Then the entire thing gets torn down and all the little niggle things get sorted and tie strapped in place. Final torque on fasteners and then, finally it’ll be done.

Hoping that’ll conclude this year….but after 4 years of stop/start, finding more crap wrong and taking care of everything I’m not gonna hold my breath.
 

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2004 GSXR 600, 1992 GSXR 750, 1983 XN85 Turbo & some Euro bikes
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Discussion Starter · #9 ·
Motor vehicle Hood Sports equipment Automotive lighting Automotive tire

One of the few digitized pics I have in random folders of the state the 750 was when I got it. that dent was a real MFer to work out. It was much deeper than it appears.I ended up tearing holes in the metal trying to work that dent out.

It meant I had to braze the holes shut and then seal the tank. I had the sealing done professionally at a radiator shop. They used a product called Red Kote which began to bleed into the fuel over time. That's the major reason I got a new to me tank. It too is damaged, but is rust free inside and hasn't been coated.
 

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2004 GSXR 600, 1992 GSXR 750, 1983 XN85 Turbo & some Euro bikes
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Discussion Starter · #10 ·
Since my last post was of the damaged tank, here’s a couple of the same tank, post repair:
Automotive lighting Automotive design Headlamp Bag Motor vehicle

This the same spot as the pic in my last post. Below, a full top view:
Automotive lighting Hood Automotive tire Motor vehicle Sports gear

As it has been some 25 years and some since the last time this tank was repaired and sealed, and 20 since the bike was last run, I think it’s held up fairly well.

Up close, I can see a few places where the lacquer has started to “check” and the filler has shrunk some but it is otherwise in good shape.
 

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2004 GSXR 600, 1992 GSXR 750, 1983 XN85 Turbo & some Euro bikes
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Discussion Starter · #11 ·
Made a couple of good finds on eBay this weekend. Found the one key part I’m missing to make my conversion to the 1988/89 body style.

I found and paid for a front sub-frame/fairing stay for an ‘88/89. Then, just after that I found a complete head light bucket to match it. It has just one head light but I have a couple to replace the missing one.

Now I have the majority of the hard parts I need to complete the conversion. I think I’ll probably need mirrors as the OEM mirrors I’m pretty sure have different mounting to the 1992.

Parts wise, I have the complete body to order, as well as emulsion tubes for the carbs. Probably will need some pilots and mains as well. Also, I have 38s so they have the “power jets” too. I’m guessing those will also need to be replaced.

Aside from simple stuff like turn signals I think the only other thing I’d like to change is the rear sets. I have an idea on them so will post that once I get there.

As I am unsure when I will eventually get around to actually doing the work required to get this project off the ground….errr; on the road rather…..updates may be sporadic and not especially detailed.
 

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Mod of the North
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You might be better off with aftermarket mirrors. I am running OEM '89 750 mirrors on my 1100 and they are very short. It is difficult (*impossible) to see directly behind me with out actually moving my arm out of the way.
 

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Mod of the North
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:ROFLMAO: Sorry, I am preaching to the chior I suppose. I forgot this isn't your first rodeo on this horse.
 

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Discussion Starter · #15 ·
:mad:
My head light bucket arrived this evening. This how it looked when I got home:
Packing materials Rectangle Wood Font Shipping box


Haven’t opened it yet….kinda reluctant to really, judging from the shape of the box, I don’t have high hopes that is isn’t mashed to bits.
 

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Mod of the North
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Oh no. It’s always the fragile stuff too. It never happens when you order engine mounts or anvils.
 

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2004 GSXR 600, 1992 GSXR 750, 1983 XN85 Turbo & some Euro bikes
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Discussion Starter · #17 ·
😅
Opened the box this morning. Looks like I dodged a bullet.
Automotive lighting Grille Motor vehicle Automotive tire Headlamp


The bucket is intact and the remaining head lamp lens is unbroken. Just awaiting the subframe now.

My plan is to install the head lamp lens from the original head lamp bucket to complete this one.

One step closer to completing my conversion.
 

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2004 GSXR 600, 1992 GSXR 750, 1983 XN85 Turbo & some Euro bikes
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Discussion Starter · #18 ·
Well….that did not go as planned. Finally dug out my old headlight bucket from the ‘92. The head lamp tabs are not spaced the same, and the square holes in the metal tabs for the adjusting screws are larger.

Not exactly the end of the world. I could modify the existing tabs so the spacing is correct and weld a piece of sheet metal in to make the holes smaller.

Then again I could wait until I see a single head lamp on eBay so I don’t have to modify anything. Still deciding. I guess if I reach the point of completion and that’s all that’s holding me up…..I’ll modify.

On another note, the front subframe is shipping tomorrow.
 

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Discussion Starter · #19 ·
Another day that did not go as planned. Got myself a PDR kit a few days ago on Amazon. Mainly I got it for the dent puller “frame” but decided to give it a go with the dents in my new to me tank.

I did not expect much but was sorely disappointed! I guess if you had a superficial dent this kit would work on that. Anything significant and not a chance in hell.

My original plan was to get the puller frame and weld a bolt to one dent and try to pull it that way. Gonna need some longer bolts though, as the puller frame is fairly thick and then there are the added support pads to account for.

Thus, I’ll be dead in the water on this until I return from vacation. Yes, vacation. I’m out for a month but get home after 3 weeks, so I have time to work on projects before going back to work.

I have just 2 work days left before we leave. See ya!!
 

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Discussion Starter · #20 ·
Update 12 September.

The new to me upper fairing/head light stay/subframe arrived today. Anyone with an ‘89 mind getting a picture of the point where the upper fairing stay mounts to the steering head? Just to give me a better mental picture. Thanks in advance. Sub.
 
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