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Complete engine rebuild Suzuki GT750-B (WL)

Some photo's of the finished GT750 engine.
Some photo's of the finished GT750 engine.
Some photo's of the finished GT750 engine.
Some photo's of the finished GT750 engine.
Some photo's of the finished GT750 engine.
Some photo's of the finished GT750 engine.
Some photo's of the finished GT750 engine.
Some photo's of the finished GT750 engine.
Some photo's of the finished GT750 engine.
Some photo's of the finished GT750 engine.
Some photo's of the finished GT750 engine.
Some photo's of the finished GT750 engine.
Some photo's of the finished GT750 engine.
Some photo's of the finished GT750 engine.
Used today my new tool for adjusting the right timing, works very fine but needs a modification.
Used today my new tool for adjusting the right timing, works very fine but needs a modification.
Adjusting the ignition points with a dial gauge for finding TDC.
Adjusting the ignition points with a dial gauge for finding TDC.
Just a photo, all wires collected so on installation they won't give problems.
Just a photo, all wires collected so on installation they won't give problems.
Just a photo.
Just a photo.
Barrel on the engine back side of the engine.
Barrel on the engine back side of the engine.
Engine almost finished, front side.
Engine almost finished, front side.
Cilinderhead installed. Torqued all the M10 and M8 bolts with the given value and on sequence. NEVER forget to RETORQUE the cilinderhead after 250km.
Cilinderhead installed. Torqued all the M10 and M8 bolts with the given value and on sequence. NEVER forget to RETORQUE the cilinderhead after 250km.
We use the RIGHT head gasket. The gasket should be shiny, all other aftermarket gaskets give problems.
We use the RIGHT head gasket. The gasket should be shiny, all other aftermarket gaskets give problems.
View on the installed barrel on the GT750 engine.
View on the installed barrel on the GT750 engine.
Finished installing the barrel on the GT750 engine. Remember this is a 2-man job.
Finished installing the barrel on the GT750 engine. Remember this is a 2-man job.
Almost finished installing the barrel.
Almost finished installing the barrel.
Almost finished installing the barrel.
Checking of nothing happened with the coolant foorter O-rings by inspecting them for the second time.
Checking of nothing happened with the coolant foorter O-rings by inspecting them for the second time.
Checking of nothing happened with the coolant foorter O-rings by inspecting them for the second time.
Ready to install the barrel? CHECK.
Ready to install the barrel? CHECK.
Installed all pistons on the right place? CHECK.
Installed all pistons on the right place? CHECK.
LEFT piston installed in the right direction? CHECK.
LEFT piston installed in the right direction? CHECK.
CENTER piston installed in the right direction? CHECK.
CENTER piston installed in the right direction? CHECK.
RIGHT piston installed in the right direction? CHECK.
RIGHT piston installed in the right direction? CHECK.
Coolant O-rings installed check first time, in total four O-rings.
Coolant O-rings installed check first time, in total four O-rings.
Coolant O-rings installed check first time.
Coolant O-rings installed check first time.
Checking if all oil holes in the footer gasket are open, in total three oil holes.
Checking if all oil holes in the footer gasket are open, in total three oil holes.
Checking if all oil holes in the footer gasket are open.
Checking if all oil holes in the footer gasket are open.
The other side of the psiton, of course we check all circlips on all three pistons.
The other side of the psiton, of course we check all circlips on all three pistons.
ALWAYS checking the circlips when installed, when you loos some you have engine damage.
ALWAYS checking the circlips when installed, when you loos some you have engine damage.
Prepairing the pistons before installing. Notice we start with the RIGHT piston which becomes on the LEFT SIDE HAND because the engine is backwards flipped.
Prepairing the pistons before installing. Notice we start with the RIGHT piston which becomes on the LEFT SIDE HAND because the engine is backwards flipped.
Cleaning and inspecting the barrel before installation.
Cleaning and inspecting the barrel before installation.
After celaning the cilinder head installing the temperature sensor, we use some sealant zo it will not leak.
After celaning the cilinder head installing the temperature sensor, we use some sealant zo it will not leak.
UPDATE 16-09-2024: Checked the thermostat in boiling hot water, the thermostat is open now so should be OK.
UPDATE 16-09-2024: Checked the thermostat in boiling hot water, the thermostat is open now so should be OK.
All parts installed on the engine.
All parts installed on the engine.
Installed oil pump on its oil lines. OF COURSE you always should do the oil pump test. We have filled the oil lines with green 2stroke oil, in the 2stroke tank is RED oil.
Installed oil pump on its oil lines. OF COURSE you always should do the oil pump test. We have filled the oil lines with green 2stroke oil, in the 2stroke tank is RED oil.
New gasket for the top of the oil pump. Be sure all oil holes are open.
New gasket for the top of the oil pump. Be sure all oil holes are open.
Cleaning and inspecting all parts of the oil pump.
Cleaning and inspecting all parts of the oil pump.
Rebuild of the oil pump, we see more frequent leaking oil pump shafts, so we replace the seal on the shaft. For this we have to sis-assemble the complete oil pump.
Rebuild of the oil pump, we see more frequent leaking oil pump shafts, so we replace the seal on the shaft. For this we have to sis-assemble the complete oil pump.
Inspecting and cleaning the electrical starter. Brushes are OK.
Inspecting and cleaning the electrical starter. Brushes are OK.
Inspecting and cleaning the electrical starter.
Inspecting and cleaning the electrical starter.
Engine clutch cover and generator cover installed to close the engine.
Engine clutch cover and generator cover installed to close the engine.
Engine ingnition cover installed to close the engine.
Engine ingnition cover installed to close the engine.
Installing the clutch: Clutch installing completed.
Installing the clutch: Clutch installing completed.
Installing the clutch: Clutch installing completed.
Installing the clutch: Clutch basket and drum.
Installing the clutch: Clutch basket and drum.
Installing the clutch: Spaver.
Installing the clutch: Spaver.
Installing the clutch: Shim ring.
Installing the clutch: Shim ring.
Starter clutch and nylon waterpump gear installed.
Starter clutch and nylon waterpump gear installed.
Starter clutch installed, nut torqued wit 45Nm.
Starter clutch installed, nut torqued wit 45Nm.
Installing the needle bearings for the starter clutch.
Installing the needle bearings for the starter clutch.
All parts are installed.
All parts are installed.
All engine surfaces have selant now, the engine can be closed.
All engine surfaces have selant now, the engine can be closed.
All parts installed correct? I allways check the two screws on the kickstarter release hook.
All parts installed correct? I allways check the two screws on the kickstarter release hook.
All parts installed correct? Oil hole in the kickstarter shaft has to be up, and the stop is installed.
All parts installed correct? Oil hole in the kickstarter shaft has to be up, and the stop is installed.
UPDATE 14-10-2024: All parts installed correct? Ring on ABOVE on the oil pump activate shaft.
UPDATE 14-10-2024: All parts installed correct? Ring on ABOVE on the oil pump activate shaft.
Installing the rebuild cranckshaft. We always check the space between the seals and the cranckshaft itself. I use a ruler to check this space. After installing these engine parts we ALWAYS wait for a day before closing the engine; This gives us time to think about everything: Did we forget something?
Installing the rebuild cranckshaft. We always check the space between the seals and the cranckshaft itself. I use a ruler to check this space. After installing these engine parts we ALWAYS wait for a day before closing the engine; This gives us time to think about everything: Did we forget something?
Installing the rebuild cranckshaft. We always check the space between the seals and the cranckshaft itself. I use a ruler to check this space.
Installing the rebuild cranckshaft. We always check the space between the seals and the cranckshaft itself. I use a ruler to check this space.
Installing the rebuild cranckshaft. We always check the space between the seals and the cranckshaft itself. I use a ruler to check this space.
Installing the rebuild cranckshaft. We always check the space between the seals and the cranckshaft itself. I use a ruler to check this space.
Installing the rebuild cranckshaft. We always check the space between the seals and the cranckshaft itself. I use a ruler to check this space.
Installing the rebuild cranckshaft. We always check the space between the seals and the cranckshaft itself. I use a ruler to check this space.
Also DON't forget the small O-ring for the coolant canal in the engine. When we start the rebuild the engine we put on this O-ring first, so we can't forget.
Also DON't forget the small O-ring for the coolant canal in the engine. When we start the rebuild the engine we put on this O-ring first, so we can't forget.
Don't forget the large C-ring for the groove bearing on the cranckshaft.
Don't forget the large C-ring for the groove bearing on the cranckshaft.
We sharpened the three worn dogs and the result is much better. Repairing the dogs will give a better result and will last much longer.
We sharpened the three worn dogs and the result is much better. Repairing the dogs will give a better result and will last much longer.
We sharpened the three worn dogs and the result is much better. Repairing the dogs will give a better result and will last much longer.
We sharpened the three worn dogs and the result is much better. Repairing the dogs will give a better result and will last much longer. Close-up of the sharpened dogs.
We sharpened the three worn dogs and the result is much better. Repairing the dogs will give a better result and will last much longer. Close-up of the sharpened dogs.
We sharpened the three worn dogs and the result is much better. Repairing the dogs will give a better result and will last much longer.
We sharpened the three worn dogs and the result is much better. Repairing the dogs will give a better result and will last much longer.
UPDATE 16-09-2024: Do you remember the secundairy gearbox shaft with it's worn dogs? We decided to repair these worn dogs. In the next foto's you will see the result.
UPDATE 16-09-2024: Do you remember the secundairy gearbox shaft with it's worn dogs? We decided to repair these worn dogs. In the next foto's you will see the result.
A test for the oil lines. Now it can hang for a couple of days: So we can see if the check-valves are OK.
A test for the oil lines. Now it can hang for a couple of days: So we can see if the check-valves are OK.
Sadly this engine had a chain break in the past, a chunck of the aluminium upper casing is broken and we see a big gap.
Sadly this engine had a chain break in the past, a chunck of the aluminium upper casing is broken and we see a big gap.
Removed all the painting tape and barrel footer cover, this engine can be used again when finished the rebuild.
Removed all the painting tape and barrel footer cover, this engine can be used again when finished the rebuild.
Another view of the painted enginen upper casing.
Another view of the painted enginen upper casing.
Did you remember this engine in the beginning? Due to the corrosion, even wet-blasting was not enough, to get this engine upper casing shiny again, so we painted it with engine paint.
Did you remember this engine in the beginning? Due to the corrosion, even wet-blasting was not enough, to get this engine upper casing shiny again, so we painted it with engine paint.
Overview of the installed gearbox parts, the rebuild cracnkshaft will be installed later.
Overview of the installed gearbox parts, the rebuild cracnkshaft will be installed later.
Checking if bthe rubber plug is in the PRIMAIRY shaft.
Checking if bthe rubber plug is in the PRIMAIRY shaft.
Checking for the rubber plug in the kickstarter shaft.
Checking for the rubber plug in the kickstarter shaft.
CLOSE-UP: Inspecting the gears on the SECUNDAIRI shaft, yes the third gear has some worn dogs but will function, there is for 80% grip on the dogs. Wrong gearbox oil is in most cases the reason for worn dogs.
CLOSE-UP: Inspecting the gears on the SECUNDAIRI shaft, yes the third gear has some worn dogs but will function, there is for 80% grip on the dogs. Wrong gearbox oil is in most cases the reason for worn dogs.
Inspecting the gears on the SECUNDAIRI shaft, yes the third gear has some worn dogs but will function, there is for 80% grip on the dogs. Wrong gearbox oil is in most cases the reason for worn dogs.
Inspecting the gears on the SECUNDAIRI shaft, yes the third gear has some worn dogs but will function, there is for 80% grip on the dogs. Wrong gearbox oil is in most cases the reason for worn dogs.
Waterpump, ref counter shaft installed, cleaned the bearings and are OK.
Waterpump, ref counter shaft installed, cleaned the bearings and are OK.
Installing the kickstarter shaft, take care that the OIL hole is up when the kickstarter rattle is released.
Installing the kickstarter shaft, take care that the OIL hole is up when the kickstarter rattle is released.
Shifter plates installed, the screws are secured with blue lock-tite and we always use the impact screwdriver.
Shifter plates installed, the screws are secured with blue lock-tite and we always use the impact screwdriver.
Installing the gear shifting forks and other parts.
Installing the gear shifting forks and other parts.
Installed impeller and secured with the small circlip.
Installed impeller and secured with the small circlip.
Installed waterpump inside the lower casing of the engine, the waterpump is secured with a large circlip.
Installed waterpump inside the lower casing of the engine, the waterpump is secured with a large circlip.
Complete assembled waterpump, ready for install.
Complete assembled waterpump, ready for install.
Waterpump housing and shaft are cleaned and polished for re-use and to rebuild the waterpump.
Waterpump housing and shaft are cleaned and polished for re-use and to rebuild the waterpump.
Waterpump, all new parts.
Waterpump, all new parts.
The mechanical seal is totaly worn and neads to be replaced.
The mechanical seal is totaly worn and neads to be replaced.
Waterpump all old and defect parts, a lot of parts we will replace by new parts: Mechanical seal, O-rings, bearing and seal. Of course we will also clean and polish the waterpump parts.
Waterpump all old and defect parts, a lot of parts we will replace by new parts: Mechanical seal, O-rings, bearing and seal. Of course we will also clean and polish the waterpump parts.
Thorough cleaning of the lower engine casing before we can assemble this engine. Cleaning all watre canals inside the engine.
Thorough cleaning of the lower engine casing before we can assemble this engine. Cleaning all watre canals inside the engine.
Thorough cleaning of the lower engine casing before we can assemble this engine. Waterpump housing have to be cleaned and polished to prevent leaking oil and/or coolant.
Thorough cleaning of the lower engine casing before we can assemble this engine. Waterpump housing have to be cleaned and polished to prevent leaking oil and/or coolant.
Thorough cleaning of the lower engine casing before we can assemble this engine.
Thorough cleaning of the lower engine casing before we can assemble this engine.
UPDATE 10-09-2024: Thorough cleaning of the lower engine casing before we can assemble this engine.
UPDATE 10-09-2024: Thorough cleaning of the lower engine casing before we can assemble this engine.
Collected parts.
Collected parts.
Soaping in the dirty engine upper casing.
Soaping in the dirty engine upper casing.
Disassembling this GT750-B engine for rebuild.
Disassembling this GT750-B engine for rebuild.
Disassembling this GT750-B engine for rebuild.
Disassembling this GT750-B engine for rebuild.
Disassembling this GT750-B engine for rebuild.
Disassembling this GT750-B engine for rebuild.
Extreem dirty GT750-B engine.
Extreem dirty GT750-B engine.
Extreem dirty GT750-B engine.
Just for tagging: Motor revisie GT750 GT550 GT380 T20 T500 GT2500 T350 krukas revisie cilinder boren en honen polijsten onderdelen waterpomp zuigers onderhoud reparatie vervanging
Just for tagging: Motor revisie GT750 GT550 GT380 T20 T500 GT2500 T350 krukas revisie cilinder boren en honen polijsten onderdelen waterpomp zuigers onderhoud reparatie vervanging
Certainly a Suzuki GT750-B engine.
Certainly a Suzuki GT750-B engine.
Extreem dirty GT750-B engine, before the rebuild this engine has to be washed and wet-blasted.
Extreem dirty GT750-B engine, before the rebuild this engine has to be washed and wet-blasted.
Finished GT750 engine, take a look on the next photo's of the total rebuild of this engine.
Finished GT750 engine, take a look on the next photo's of the total rebuild of this engine.

Parts for this bike

All parts Suzuki GT750

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