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Maintenance and repair Suzuki GT750-B (CL)

Job completed on this place of the engine.
Job completed on this place of the engine.
We replaced ALL the coolant hoses.
We replaced ALL the coolant hoses.
We replaced ALL the coolant hoses.
We replaced ALL the coolant hoses. The removed bad hose was almost cut in half due to wrong clamps.
We replaced ALL the coolant hoses. The removed bad hose was almost cut in half due to wrong clamps.
Clean and refurbished electrical starter. Of course we always do a bench check if it works fine. Notice the much longer PLUS brush.
Clean and refurbished electrical starter. Of course we always do a bench check if it works fine. Notice the much longer PLUS brush.
Clean and refurbished electrical starter. Of course we always do a bench check if it works fine.
Clean and refurbished electrical starter. Of course we always do a bench check if it works fine.
When you have a job to do at this place on the engine ALWAYS check, clean and repair the electrical starter. In this case the electrical starter was very dirty and the PLUS brush was almost gone.
When you have a job to do at this place on the engine ALWAYS check, clean and repair the electrical starter. In this case the electrical starter was very dirty and the PLUS brush was almost gone.
When you have a job to do at this place on the engine ALWAYS check, clean and repair the electrical starter. In this case the electrical starter was very dirty and the PLUS brush was almost gone.
Installed a rebuild oil pump on the oil lines. Of course we will do the oil pump test when the engine runs again. You can see this test in this link: https://youtu.be/yCy-eMetm4U?si=7Zxxb0J6_wNwHJqJ
Installed a rebuild oil pump on the oil lines. Of course we will do the oil pump test when the engine runs again. You can see this test in this link: https://youtu.be/yCy-eMetm4U?si=7Zxxb0J6_wNwHJqJ
Installed oil lines. NOTE that on the outer LG oil line we have installed a check-valve.
Installed oil lines. NOTE that on the outer LG oil line we have installed a check-valve.
Installed the refurbished oil lines, as there is RED 2stroke oil in the 2stroke oil tank, we need to fill the oil lines with another colored 2stroke oil.
Installed the refurbished oil lines, as there is RED 2stroke oil in the 2stroke oil tank, we need to fill the oil lines with another colored 2stroke oil.
New refurbished oil lines. We installed six new check-valves. Of course we did a 24hrs hangtest.
New refurbished oil lines. We installed six new check-valves. Of course we did a 24hrs hangtest.
It's good to change the gearbox oil.
It's good to change the gearbox oil.
Installing the SRIS valves and hoses. Most hoses were cracked and leaked. We needed to install new hoses.
Installing the SRIS valves and hoses. Most hoses were cracked and leaked. We needed to install new hoses.
The signal wiring harnas is BURNED and MELTED by the hot exhaust. It was clear what caused this, the cable guide for the ignition wiring is installed on the wrong place. We will install a new elektronic ignition.
The signal wiring harnas is BURNED and MELTED by the hot exhaust. It was clear what caused this, the cable guide for the ignition wiring is installed on the wrong place. We will install a new elektronic ignition.
The signal wiring harnas is cracked, notice that the wires inside are very thin and delicate.
The signal wiring harnas is cracked, notice that the wires inside are very thin and delicate.
We needed to remove a lot of parts on the bike to get to the places where we need to do some work.
We needed to remove a lot of parts on the bike to get to the places where we need to do some work.
We needed to remove a lot of parts on the bike to get to the places where we need to do some work.
Removed bolt 13. We will install bolt 13 in the correct way.
Removed bolt 13. We will install bolt 13 in the correct way.
As we seen a oil wet engine bottom we noticed that BOLT 13 (again) was leaking oil. Someone didn't read the manual. After the bolt is removed we see teflon tape arround this bolt. That's not the correct way to prevent oil leakage at bolt 13.
As we seen a oil wet engine bottom we noticed that BOLT 13 (again) was leaking oil. Someone didn't read the manual. After the bolt is removed we see teflon tape arround this bolt. That's not the correct way to prevent oil leakage at bolt 13.
Nice refurbished front calipers.
Nice refurbished front calipers.
Nice refurbished front calipers.
See the difference, the upper brake pads all drenched on brake fluid. This is dangerous. We will install new fresh brake pads.
See the difference, the upper brake pads all drenched on brake fluid. This is dangerous. We will install new fresh brake pads.
Fresh painted caliper parts. We will assemble the calipers and install new brake pads.
Fresh painted caliper parts. We will assemble the calipers and install new brake pads.
The other caliper, looks like it is leaking.
The other caliper, looks like it is leaking.
Yes we do need a respray of the calipers. You should no that the brake fluid is very aggressive to paint.
Yes we do need a respray of the calipers. You should no that the brake fluid is very aggressive to paint.
Dis-assembling a front caliper, we also found some corrosion and brake fluid leakage.
Dis-assembling a front caliper, we also found some corrosion and brake fluid leakage.
After assembling the master brake cilinder we installed it back on the bike.
After assembling the master brake cilinder we installed it back on the bike.
After assembling the master brake cilinder we installed it back on the bike.
Cleaning the master brake cilinder inside and cleaning all the other parts.
Cleaning the master brake cilinder inside and cleaning all the other parts.
We dis-assembeled the complere master brake cilinder.
We dis-assembeled the complere master brake cilinder.
As we found some corrosion on the master brake cilinder we needed to clean and repair the master brake cilinder.
As we found some corrosion on the master brake cilinder we needed to clean and repair the master brake cilinder.
When you find some corrosion on the lower side of a caliper it is most common that a caliper has leakd brake fluid. YES, you need to repair that.
When you find some corrosion on the lower side of a caliper it is most common that a caliper has leakd brake fluid. YES, you need to repair that.
When you find some corrosion on the lower side of a caliper it is most common that a caliper has leakd brake fluid. YES, you need to repair that.
And we rerouted the wiring looms of this GT750. Looks much better now and all wirings reach the correct place.
And we rerouted the wiring looms of this GT750. Looks much better now and all wirings reach the correct place.
And we rerouted the wiring looms of this GT750. Looks much better now and all wirings reach the correct place.
So we repaired the possible shortcuts with new isolated connectors.
So we repaired the possible shortcuts with new isolated connectors.
As we needed to open the headlight for the repair of the cockpit we found two NOT isolated connections. This can create a shortcut.
As we needed to open the headlight for the repair of the cockpit we found two NOT isolated connections. This can create a shortcut.
Fresh installed cockpit. This looks much better now.
Fresh installed cockpit. This looks much better now.
As we don't have the special bolts we needed to create someting which looks like genuine. So, installed cushion for the cockpit, we made two bushings and installed the cokpit with two handle bar bolts.
As we don't have the special bolts we needed to create someting which looks like genuine. So, installed cushion for the cockpit, we made two bushings and installed the cokpit with two handle bar bolts.
Corrected the plastic cover plate with tw new screws M4.
Corrected the plastic cover plate with tw new screws M4.
Missing the lower longer M4 screws. We placed new screws. Notice the loom of the temperature gauge, this loom is between the plastic cover plate but should be outside the cover plate.
Missing the lower longer M4 screws. We placed new screws. Notice the loom of the temperature gauge, this loom is between the plastic cover plate but should be outside the cover plate.
Why not use some bolts which you would like to use on the bike? These bolts should be special bolts with a hex head 14, bushing and M8 threading.
Why not use some bolts which you would like to use on the bike? These bolts should be special bolts with a hex head 14, bushing and M8 threading.
Discovered again some problems on the cockpit on the GT750. Missing screws and wrong installed wiring. The missings screws hold the plate voor the ignition key lock. We will correct this problem.
Discovered again some problems on the cockpit on the GT750. Missing screws and wrong installed wiring. The missing screws hold the plate for the ignition key lock. We will correct this problem.
SITE UPDATE 03092026: Normaly all the connectors are connected INSIDE the headlight. In this case, de loom of the gear indicator was connected ouitside the headlight. Of course we will correct this connection.
SITE UPDATE 03092026: Normaly all the connectors are connected INSIDE the headlight. In this case, de loom of the gear indicator was connected ouitside the headlight. Of course we will correct this connection.
The hose connection between the coolant filler opening and the radiator looks bad, like the hose has been melted. If this hose connection will leak coolant it is possible you get wounded. We will replace the hose and use new clamps.
The hose connection between the coolant filler opening and the radiator looks bad, like the hose has been melted. If this hose connection will leak coolant it is possible you get wounded. We will replace the hose and use new clamps.
The hose connection between the cooler filler opening and the radiator looks bad, like the hose has been melted. If this hose connection will leak coolant it is possible you get wounded.
The hose connection between the cooler filler opening and the radiator looks bad, like the hose has been melted. If this hose connection will leak coolant it is possible you get wounded.
Now the connector for the rear light connections are accessible agin.
Now the connector for the rear light connections are accessible agin.
Electro panel on it's place again.
Electro panel on it's place again.
And of course there is always spaghetti first. No problem we know how to install electricity.
And of course there is always spaghetti first. No problem we know how to install electricity.
This is the right side for installing the wiring looms.
This is the right side for installing the wiring looms.
Routing the wiring looms on the right side and on the RIGHT of the frame. As the wiring looms protection is broken we will aslo repair this.
Routing the wiring looms on the right side and on the RIGHT of the frame. As the wiring looms protection is broken we will aslo repair this.
See the red lines and follow the arrow, that's the place of the cable on the frame.
See the red lines and follow the arrow, that's the place of the cable on the frame.
Wrong routed wiring looms behind the electro panel, this means that the connector for the rear lights is behind the installed electro panel.
Wrong routed wiring looms behind the electro panel, this means that the connector for the rear lights is behind the installed electro panel.
Good example: Here yoiu can see that wiring loom for the electro panel are on the wrong side and at the wrong place for the connections.
Good example: Here yoiu can see that wiring loom for the electro panel are on the wrong side and at the wrong place for the connections.
So, for the rerouting of all the cables we disconnect all connectors and others. We found one ground connection to the frame not connected.
So, for the rerouting of all the cables we disconnect all connectors and others. We found one ground connection to the frame not connected.
Oh no! All wiring looms routed at the wrong side of the frame. This can mean that where there is a split for connections it won't fit. On the frame there are provision for, for routing the wiring looms in the correct way. It is also possible that due to the wrong routing there will be chafing on the wires which can cause shortcuts.
Oh no! All wiring looms routed at the wrong side of the frame. This can mean that where there is a split for connections it won't fit. On the frame there are provision for, for routing the wiring looms in the correct way. It is also possible that due to the wrong routing there will be chafing on the wires which can cause shortcuts.
After removing the airbox and the carburetors we cleaned the TOP side of the engine first. So we can work better for removing the critical engine parts such as the oil pump and the oil lines. Both we will be rebuild.
After removing the airbox and the carburetors we cleaned the TOP side of the engine first. So we can work better for removing the critical engine parts such as the oil pump and the oil lines. Both we will be rebuild.
After removing the airbox and the carburetors we cleaned the TOP side of the engine first. So we can work better for removing the critical engine parts such as the oil pump and the oil lines. Both we will be rebuild.
A lot of leaked gearbox oil. If the rebuilder had read the maintenance manual there shouldn't be this oil leak.
A lot of leaked gearbox oil. If the rebuilder had read the maintenance manual there shouldn't be this oil leak.
See red arrow: AGAIN, someone didn't read the maintenance manual about BOLT 13 on the engine rebuild. You need to install this bolt in a special way. In this case (agian) leaking gearbox oil.
See red arrow: AGAIN, someone didn't read the maintenance manual about BOLT 13 on the engine rebuild. You need to install this bolt in a special way. In this case (agian) leaking gearbox oil.
AGAIN, someone didn't read the maintenance manual about BOLT 13 on the engine rebuild. You need to install this bolt in a special way. In this case (agian) leaking gearbox oil.
AGAIN, someone didn't read the maintenance manual about BOLT 13 on the engine rebuild. You need to install this bolt in a special way. In this case (agian) leaking gearbox oil.
Drainen the carters of the GT750 engine. For sofar OK. The center cilinder had some 2stroke oil inside.
Drainen the carters of the GT750 engine. For sofar OK. The center cilinder had some 2stroke oil inside.
Wrong installed crown nuts on the exhaust manifold. Always keep at least 2mm distance between the cilinder block and the crown nut.
Wrong installed crown nuts on the exhaust manifold. Always keep at least 2mm distance between the cilinder block and the crown nut.
Wrong installed crown nuts on the exhaust manifold. Always keep at least 2mm distance between the cilinder block and the crown nut.
We found the oil pump connection rod loose, WHY? The client told us that he did it himself and the engine always got enough 2stroke oil. CHECK.
We found the oil pump connection rod loose, WHY? The client told us that he did it himself and the engine always got enough 2stroke oil. CHECK.
We found the oil pump connection rod loose, WHY? The client told us that he did it himself and the engine always got enough 2stroke oil. CHECK.
We found one rusty and old throttle cable, we will install a new set of throttle cables.
We found one rusty and old throttle cable, we will install a new set of throttle cables.
We found one rusty and old throttle cable, we will install a new set of throttle cables. By the way, we found the master brake cilinder leaking also. The master brake cilinder will be rebuild.
We found one rusty and old throttle cable, we will install a new set of throttle cables. By the way, we found the master brake cilinder leaking also. The master brake cilinder will be rebuild.
We at www.knalnaarpotz.nl NEVER start a new (unknown) arrived two stroke bike. We always drain the engine first before starting maintenance and starting the engine. after that we know which job's we have to do extra.
We at www.knalnaarpotz.nl NEVER start a new (unknown) arrived two stroke bike. We always drain the engine first before starting maintenance and starting the engine. after that we know which job's we have to do extra.
On the lowest point on the front calipers we found some corrosion. This means a slightly leak of the aggressive brake fluid. We will rebuild the calipers.
On the lowest point on the front calipers we found some corrosion. This means a slightly leak of the aggressive brake fluid. We will rebuild the calipers.
On the lowest point on the front calipers we found some corrosion. This means a slightly leak of the aggressive brake fluid. We will rebuild the calipers.
Inner fork tubes and seals are OK. We lifted the dust caps for a better check.
Inner fork tubes and seals are OK. We lifted the dust caps for a better check.
POV: New project maintenace and repair on a Suzuki GT750-B. FIRST WE CHECK THE GT750-B FOR VISABLE PROBLEMS FOR MAINTENACE AND REPAIR.
POV: New project maintenace and repair on a Suzuki GT750-B. FIRST WE CHECK THE GT750-B FOR VISABLE PROBLEMS FOR MAINTENACE AND REPAIR.
POV: New project maintenace and repair on a Suzuki GT750-B.
POV: New project maintenace and repair on a Suzuki GT750-B.
POV: New project maintenace and repair on a Suzuki GT750-B.
POV: New project maintenace and repair on a Suzuki GT750-B.
POV: New project maintenace and repair on a Suzuki GT750-B.
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
22082026 STARTING A NEW PROJECT: Maintenance and repair on a SUZUKI GT750-B.
22082026 STARTING A NEW PROJECT: Maintenance and repair on a SUZUKI GT750-B.

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