Welcome to the forum. Sorry, but I can't help with the manual, but I am sure one of the other guy's will be able to.
I can answer some of your questions though.
1: The front and rear suspension is pretty soft. I was told 200 a piece for rear shocks. Would a bike scrapyard be a potential way around that or am i stuck with what I have until I spend the $$$$?
Look at vintagecb750.com and partsandmore.com for shocks. I bought a pair of progressive shocks, for less then $90.00 from partsandmore.com
2: The front fork parts are all pretty spendy too for a rebuild with new parts. what are the odds of getting good results by rebuilding with existing parts and is this a potential DIY project?
All, you need to rebuild the front forks are fork seals, a qt of ATF, and maybe dust boots. Cycle-X has the seals, for $7.00, vintagecb750 has the seals, for $12.00, and the dust boots. As, for instructions on how to do it, look, for "My Buddies POW/MIA Bike" in the build section. I have a step by step photo layout of it.
3: Throttle hangs quite a bit or just comes down slowly. the linkage at the carbs returns fine. Is there something sticking in the carb?
Does the cable need lubed, or replaced?
4: The bike has a really significant difference in power when you hit 3k rpm. are these motors just weak at low rpm or could it be an ignition or carb problem?
The carbs might need cleaned.
5: Right around 7500 rpm there is a loud buzzing sound, but its only between maybe 7500 and 7600. any ideas?
No.
6: I need to change out the sprockets anyway and from what I hear, plugging the little sludge factory (self oiler) is easy if youre working in there. Has anybody done this and are they glad they did?
If the bike is self oiling, it needs a new counter shaft seal. On the contrary to what a lot of people have been led to believe. These bikes never did have an automatic chain oilier!!!!
7: I can get a K&N air filter for around the same price as oem. Is rejetting necessary with a different filter like that?
Should not need to re-jet if, you just use the K&N replacement filter in the stock airbox.
TOOLS
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I just can't imagine what could go wrong.
No fire? No explosions? So whats the point of your story?
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It couldn't be done, but the darn fool didn't know it, and did it anyway.
We all got problems. Ksharp
I like vintage bikes because they take me away from the clutter of technology that I work with everyday and back to a simpler time of mechanical elegance and simplicity.. "ninadm"
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"Fear nothing, attack everything" Eric Berry
" Oh, you read that on the internet? Clearly it IS a massive problem. Of course it CAN’t be normal operation."
1976 CB 750-A X 2
1977 CB 750-A X 4
1977 CB 750-K
1976 CB 750 F
1981 CB 750
1966 Kawasaki SG 250
1981 KZ 750 LTD
1973 CB 350
1979 CM 185 Twinstar
1982 Honda XL 80
South of Eden (Kansas City MO)