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1985 GSX750SF/S3 bottom end rebuild advice

Discussion in 'Tech Help' started by bikeGuy, Apr 2, 2016.

  1. bikeGuy
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    bikeGuy New Member

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    Hi all,

    I'm finally rebuilding my 1985 GSX750S3 (pop-up headlight) Katana after a complete strip-down 6 years ago.

    What I've now noticed is that the Suzuki service manual and parts microfiche doesn't appear to cover the Katana models to my satisfaction and I'm hoping that someone here may be able to offer advice on the oil jets and also the fitting of the 'Valve Assembly,piston Oil', really the factory manual leaves a lot to be desired. Check out part 33 from the provided fiche diagram, the part does not tightly fit the cases channel and would just rattle around if I followed the manual, I'm wondering if the manual covered the GSX750 non Katana models???

    The part is clearly a pressure regulated directional valve so I would expect that it should fit firmly and be held in place more than the case allows.

    Does anyone on here have any real experience on the bottom end engine rebuilds for the 1984-85 popup headlight GSX750 Katana, any first hand advice would be appreciated, thanks.

    Sean
     

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    Last edited: Apr 3, 2016
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  2. davo231481
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    davo231481 Member

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    wont it fit up into a recess on the engine case directly above. I've got an 84 gsx750 Es floater in the shed and can check that when I get home tomorrow
     
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  3. bikeGuy
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    bikeGuy New Member

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    Hi Davo,

    Hey thanks mate, so you recon it fits into the above, bottom half of the split crankcasing? If you recon it does I can re-split the closed cases and fit it but does it fit tight into the oil chanel with just the o-ring or need a spring to prevent movement?
     
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  4. bikeGuy
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    bikeGuy New Member

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    Hi Davo,

    Hey mate if your offer to check and compare your 84 GSX engine is still good then I'd be happy to make a trip out to meet, even offer some cash for beer :)

    I've got everything ready to seal and bolt up the engine however i'm still not 100% happy with the two different oil jet locations and orientations, if the oil jets are not right then the rebuild won't last long.

    I'd be happy to come on out and simply inspect the yet fitment on the top half of the crankcase, there are 4 jets which are visible from the top down view next to the conrods. I've chatted with the guys at Dahlitz but they were not able to offers the specifics on what oil jet goes where and which orientation. Seems nobody around town knows these mid 80's engines too well.

    Cheers, Sean
     
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  5. davo231481
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    davo231481 Member

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    Pm sent
     
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