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Maintenance and repair Suzuki GT500 (HLB)

The crankshaft will get a complete rebuild.
The crankshaft will get a complete rebuild.
Bad an rusty crankshaft bearing. This bearing is stuck because of the rust in it.
Bad an rusty crankshaft bearing. This bearing is stuck because of the rust in it.
A lot of rust on the cilinder wall. this one needs to be bored and honed agian.
A lot of rust on the cilinder wall. this one needs to be bored and honed agian.
See the difference on the cilinders, one of a T500 and the other of a GT500. This won't work as these different bikes have different timing. We replaced the T500 cilinder for the right one.
See the difference on the cilinders, one of a T500 and the other of a GT500. This won't work as these different bikes have different timing. We replaced the T500 cilinder for the right one.
The engine on the engine rebuild table.
The engine on the engine rebuild table.
The engine on the engine rebuild table.
After a couple of hours the engine is out of the frame.
After a couple of hours the engine is out of the frame.
After a couple of hours the engine is out of the frame.
Removed piston.
Removed piston.
We tried a lot of things to turn over the crankshaft, the crankshaft just turned a couple of degrees. We also removed the complete clutch. The crankshaft still wouldn't turn over. CONCLUSION: BAD CRANKSHAFT.
We tried a lot of things to turn over the crankshaft, the crankshaft just turned a couple of degrees. We also removed the complete clutch. The crankshaft still wouldn't turn over. CONCLUSION: BAD CRANKSHAFT.
Houston we have a problem........... We started to check the ignition, for that you have to turn over the crankshaft, that was not possible. What's wrong? For inspection we removed the cilinders and pistons.
Houston we have a problem........... We started to check the ignition, for that you have to turn over the crankshaft, that was not possible. What's wrong? For inspection we removed the cilinders and pistons.
Always bend the secure washer on three places. We have bend it two times extra.
Always bend the secure washer on three places. We have bend it two times extra.
Close up of the rear wheel with new tire.
Close up of the rear wheel with new tire.
Another POV.
Another POV.
Another POV.
The rear tire was also very old and need to be replaced. So we removed the wheel for changing the rear tire.
The rear tire was also very old and need to be replaced. So we removed the wheel for changing the rear tire.
Complete assembled and rebuild caliper installed on the bike again..
Complete assembled and rebuild caliper installed on the bike again..
Almost complete assembled and rebuild caliper.
Almost complete assembled and rebuild caliper.
Almost complete assembled and rebuild caliper.
New brake hose installed with new copper rings on the master brake cilinder.
New brake hose installed with new copper rings on the master brake cilinder.
Installed new brake hoses.
Installed new brake hoses.
Another POV of the rebuild master brake cilinder.
Another POV of the rebuild master brake cilinder.
Master brake cilinder usable and installed again, of course we installed the new brake hoses..
Master brake cilinder usable and installed again, of course we installed the new brake hoses..
It's always a thing to remove the deep installed circlip, of course we manage it with special tools.
It's always a thing to remove the deep installed circlip, of course we manage it with special tools.
A lot of corrosion inside the reservoir of the master brake cilinder. Don't forget to poke the small return hole at the bottom of the reservoir.
A lot of corrosion inside the reservoir of the master brake cilinder. Don't forget to poke the small return hole at the bottom of the reservoir.
When the caliper has severe corrosion, the master brake cilinder should have also have corrosion.
When the caliper has severe corrosion, the master brake cilinder should have also have corrosion.
Due to the leaking brake fluid we needed to paint the caliper.
Due to the leaking brake fluid we needed to paint the caliper.
All parts for the caliper.
All parts for the caliper.
Very dirty with much corrosion.
Very dirty with much corrosion.
Nope the brake piston is to far gone to use it agian. So we used a brake rebuild kit to rebuild the caliper.
Nope the brake piston is to far gone to use it agian. So we used a brake rebuild kit to rebuild the caliper.
Severe coorrsion.
Severe coorrsion.
Due to severe corrosion by the aggressive brake fluid the brake piston was stuck rock solid.
Due to severe corrosion by the aggressive brake fluid the brake piston was stuck rock solid.
Cleaning all the parts of the caliper.
Cleaning all the parts of the caliper.
Disassembled the front brake caliper.
Disassembled the front brake caliper.
Getting the old brake fluid ouit of the brake system, so we can rebuild the complete brake system.
Getting the old brake fluid ouit of the brake system, so we can rebuild the complete brake system.
New brake hoses.
New brake hoses.
What can you expect of a bike of 50years old? Yes the brake hoses were bad and need to bee replaced.
What can you expect of a bike of 50years old? Yes the brake hoses were bad and need to bee replaced.
Installed the rebuild front fork tubes and the frontwheel.
Installed the rebuild front fork tubes and the frontwheel.
Installed the rebuild front fork tubes and the frontwheel.
Sadly you can't buy new front fork inner tubes, so we have to deal with some pitting. The client has to do some research to get new inner tubes or getting the inner tubes rechromed agian.
Sadly you can't buy new front fork inner tubes, so we have to deal with some pitting. The client has to do some research to get new inner tubes or getting the inner tubes rechromed agian.
We rebuild both front fork tubes, so new seals and new oil.
We rebuild both front fork tubes, so new seals and new oil.
So new front tire installed.
So new front tire installed.
One front fork removed.
One front fork removed.
Leaking frontfork at the bottom, after oil there was not many oil left.
Leaking frontfork at the bottom, after oil there was not many oil left.
Leaking frontfork at the bottom, after oil there was not many oil left.
Starting to disassemble the complete frontfork to be rebuild. Both frontforks are leaking oil on the bottom.
Starting to disassemble the complete frontfork to be rebuild. Both frontforks are leaking oil on the bottom.
SITE UPDATE 09072026: Checking the tires, we, at KnalNaarPotz, will not allow to ride on a bike with tires from the year 1987! This one needs to be replaced immediately.
SITE UPDATE 09072026: Checking the tires, we, at KnalNaarPotz, will not allow to ride on a bike with tires from the year 1987! This one needs to be replaced immediately.
Installed the rebuild oil lines on the engine.
Installed the rebuild oil lines on the engine.
Installed the feeding 2stroke oil hose. Also repaired the connections on the brake switch to original.
Installed the feeding 2stroke oil hose. Also repaired the connections on the brake switch to original.
Installed the rebuild GT500 2stroke oil pump on the engine.
Installed the rebuild GT500 2stroke oil pump on the engine.
Installed the rebuild GT500 2stroke oil pump on the engine.
Rebuild GT500 2stroke oil pump.
Rebuild GT500 2stroke oil pump.
Rebuild GT500 2stroke oil pump.
Hangtest on the oil lines again to check the check-valves for leaking. PASSED.
Hangtest on the oil lines again to check the check-valves for leaking. PASSED.
Installing new check-valves on the oil lines.
Installing new check-valves on the oil lines.
All parts inside the oil pump.
All parts inside the oil pump.
Disassembling the oil pump.
Disassembling the oil pump.
Removed the oil pump form the engine.
Removed the oil pump form the engine.
Hangtest of the oil lines to check the check-valves for leaking. We rebuild the oil lines anyway.
Hangtest of the oil lines to check the check-valves for leaking. We rebuild the oil lines anyway.
Found the top seal at the back of the oil pump.
Found the top seal at the back of the oil pump.
Removing the carburators for removing the oil lines.
Removing the carburators for removing the oil lines.
Severe leaking oil pump. This oil pump needs to be rebuild completely.
Severe leaking oil pump. This oil pump needs to be rebuild completely.
Dashboard of the Suzuki GT500.
Dashboard of the Suzuki GT500.
This connector wasn't connected anymore.
This connector wasn't connected anymore.
Leaking 2stroke oil behind the cilinders.
Leaking 2stroke oil behind the cilinders.
A lot of leaking (2stroke) oil.
A lot of leaking (2stroke) oil.
On the outside a well maintained and nice GT500.
On the outside a well maintained and nice GT500.
On the outside a well maintained and nice GT500. SADLY, after doing our maintenance job we found a lot of things where it WAS NOT SAVE to ride this bike! What we have found you will see on the next photo report.
On the outside a well maintained and nice GT500. SADLY, after doing our maintenance job we found a lot of things where it WAS NOT SAVE to ride this bike! What we have found you will see on the next photo report.
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
After the client bought this very nice GT500 KnalNaarPotz was asked to do thorough maintenance and repair on this GT500. Buddy seat removed to do the maintenance.
After the client bought this very nice GT500 KnalNaarPotz was asked to do thorough maintenance and repair on this GT500. Buddy seat removed to do the maintenance.

Parts for this bike

All parts Suzuki GT500-T500-T350-T250-T20

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