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Maintenance and repair Suzuki GT380 (RS)

Found an empty casing below the 2stroke oil tank, this is the place for some maintenance tools. So we put a genuine SUZUKI tool set in it.
Found an empty casing below the 2stroke oil tank, this is the place for some maintenance tools. So we put a genuine SUZUKI tool set in it.
We repaired the trip meter knob on the speedometer.
We repaired the trip meter knob on the speedometer.
Installed the air filter and housing.
Installed the air filter and housing.
Installed the air filter and housing.
We started to complete this GT380 again: Installed the carburetors.
We started to complete this GT380 again: Installed the carburetors.
SITE UPDATE 07072026: We installed a new grabrail on this GT380. Yes that looks much better.
SITE UPDATE 07072026: We installed a new grabrail on this GT380. Yes that looks much better.
SITE UPDATE 07072026: We installed a new grabrail on this GT380. Yes that looks much better.
The cam shaft LUBRICATING velt DOES NOT hit the cam shaft. This means that contact point rocker will wear extremaly fast. So we repaired this and did some lubrication.
The cam shaft LUBRICATING velt DOES NOT hit the cam shaft. This means that contact point rocker will wear extremaly fast. So we repaired this and did some lubrication.
Find what is wrong........
Find what is wrong........
Nice coffee braun sparkplugs.
Nice coffee braun sparkplugs.
Installing the rebuild oil lines and oil pump completed.
Installing the rebuild oil lines and oil pump completed.
Installing the rebuild oil lines.
Installing the rebuild oil lines.
Installing the rebuild oil lines.
The rebuild oil lines with new check-valves. We do a hangtest to check if the check-valves are OK with oil.
The rebuild oil lines with new check-valves. We do a hangtest to check if the check-valves are OK with oil.
Rebuild oil pump, we always do a bench-chekc on the oil pump and passed the test. On the running engine we do a complete "hot" oil pump test.
Rebuild oil pump, we always do a bench-chekc on the oil pump and passed the test. On the running engine we do a complete "hot" oil pump test.
Rebuilding the oil pump, we install a new lever shaft seal, a new rotor shaft (bottom) seal and of course a new gasket.
Rebuilding the oil pump, we install a new lever shaft seal, a new rotor shaft (bottom) seal and of course a new gasket.
SIX new check-valves. Available in de KnalNaarPotz web shop.
SIX new check valves. Available in the KnalNaarPotz web shop.
The oil lines with the old check-valves. We experienced that after all these years the check-valves will leak oil into the engine.
The oil lines with the old check-valves. We experienced that after all these years the check-valves will leak oil into the engine.
Sometimes we don't understand why oil lines keep leaking on new check-valves. So the first thing to do is a hangtest for new check-valves.
Sometimes we don't understand why oil lines keep leaking on new check-valves. So the first thing to do is a hangtest for new check-valves.
Next thing to do is rebuild the oil lines and oil pump. we install new check-valves on the oil lines.
Next thing to do is rebuild the oil lines and oil pump. we install new check-valves on the oil lines.
Next thing to do is rebuild the oil lines and oil pump. we install new check-valves on the oil lines.
Next thing to do is rebuild the oil lines and oil pump. we install new check-valves on the oil lines.
Next thing to do is rebuild the oil lines and oil pump. we install new check-valves on the oil lines.
So we we cleaned and rebuild the master brake cilinder.
So we we cleaned and rebuild the master brake cilinder.
Not much leaking brake fluid on the master brake cilinder, but we disassembled the master brake cilinder, that was a good thing to do. The small return hole was almost totally clogged.
Not much leaking brake fluid on the master brake cilinder, but we disassembled the master brake cilinder, that was a good thing to do. The small return hole was almost totally clogged.
The mainbrake cilinder cap was leaking brake fluid. it is possible that the missing membrane plate caused the leakage.
The mainbrake cilinder cap was leaking brake fluid. it is possible that the missing membrane plate caused the leakage.
Also a lot of corrosion between the brake pad holder and the bake pad itself. We will also clean this part of the caliper.
Also a lot of corrosion between the brake pad holder and the bake pad itself. We will also clean this part of the caliper.
Barke pads are new.
Barke pads are new.
Corrosion.......... Clean the caliper en find where it leaks.
Corrosion.......... Clean the caliper en find where it leaks.
The seal is leaking brake fluid, due to a damaged brake piston.
The seal is leaking brake fluid, due to a damaged brake piston.
Corrosion, brake fluid is very agressive to aluminum and paint, so when you find corrosion you know there is something leaking.
Corrosion, brake fluid is very agressive to aluminum and paint, so when you find corrosion you know there is something leaking.
Bad front brake hoses. We need to replace these hoses by new.
Bad front brake hoses. We need to replace these hoses by new.
For normal maintenace we use a CHECK-LIST so we can't forget critical points on these older bikes. Found here bad front brake hoses
For normal maintenace we use a CHECK-LIST so we can't forget critical points on these older bikes. Found here bad front brake hoses
Very nice restored GT380. Signed by............................
Very nice restored GT380. Signed by............................
Very nice restored GT380.
Very nice restored GT380.
Very nice restored GT380.
Very nice restored GT380.
Very nice restored GT380.
Very nice restored GT380.
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
SUZUKI GT380 Maintenance and repair. REBUILD critical items: Oil pump and Oil lines.
SUZUKI GT380 Maintenance and repair. REBUILD critical items: Oil pump and Oil lines.

Parts for this bike

All parts Suzuki GT380

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