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Komplette Motorrevision Suzuki GT750-K (CV)

Adjusting the carburetors, and inspecting several critical points on the engine on a running GT750 engine on the test stand. ENGINE PASSED ALL TESTS. This engine can go back to the client.
Adjusting the carburetors, and inspecting several critical points on the engine on a running GT750 engine on the test stand. ENGINE PASSED ALL TESTS. This engine can go back to the client.
Adjusting the carburetors, and inspecting several critical points on the engine on a running GT750 engine on the test stand.
Adjusting the carburetors, and inspecting several critical points on the engine on a running GT750 engine on the test stand.
Another POV, see the paper with things to do on the engine.
Another POV, see the paper with things to do on the engine.
GT750 engine rebuild completed.
GT750 engine rebuild completed.
GT750 engine rebuild completed.
SITE UPDATE 27072026: As we have a GT750 engine test stand at KnalNaarPotz shop we installed the clients engine on it. We made a FIRST RUN on the engine to inspect a lot of points on the engine. ENGINE TEST PASSED after the complete rebuild.
SITE UPDATE 27072026: As we have a GT750 engine test stand at KnalNaarPotz shop we installed the clients engine on it. We made a FIRST RUN on the engine to inspect a lot of points on the engine. ENGINE TEST PASSED after the complete rebuild.
All three carburetors cleaned and rebuild.
All three carburetors cleaned and rebuild.
Cleaned carburetors.
Cleaned carburetors.
Cleaned float bowl, YES poke all holes to be sure if they are open.
Cleaned float bowl, YES poke all holes to be sure if they are open.
Carburetors: POV, Very dirty, damaged, clogged, corroded and leaking.
Carburetors: POV, Very dirty, damaged, clogged, corroded and leaking.
Carburetors: POV, Very dirty, damaged, clogged, corroded and leaking.
Carburetors: POV, cleaned two of them already.
Carburetors: POV, cleaned two of them already.
CARBURETORS: POV, as we got them from the client to rebuild for re-use. It is hard to beleave that these carburetors came from a running engine, most channels and holes clogged, very dirty, corroded and leaking. Also several screws and threading damaged, We had a lot of word to rebuild these carburetors.
CARBURETORS: POV, as we got them from the client to rebuild for re-use. It is hard to beleave that these carburetors came from a running engine, most channels and holes clogged, very dirty, corroded and leaking. Also several screws and threading damaged, We had a lot of word to rebuild these carburetors.
Installed a new thermostat.
Installed a new thermostat.
Almost finished the rebuild of a GT750 engine. We will do a engine run.
Almost finished the rebuild of a GT750 engine. We will do a engine run.
Almost finished the rebuild of a GT750 engine. We will do a engine run.
Almost finished the rebuild of a GT750 engine. We will do a engine run.
Almost finished the rebuild of a GT750 engine. We will do a engine run.
All new brushes, a clean collector and finaly a rebuild elektrical starter. Of course we do a bench-check before installing.
All new brushes, a clean collector and finaly a rebuild elektrical starter. Of course we do a bench-check before installing.
All new brushes, a clean collector and finaly a rebuild elektrical starter. Of course we do a bench-check before installing.
The monus brush is also to far gone to leave it in this way. When the wire of the brush hits the brush holder the contact to the collector is gone and the elektrical starter stops working.
The monus brush is also to far gone to leave it in this way. When the wire of the brush hits the brush holder the contact to the collector is gone and the elektrical starter stops working.
Soldering new brushes on the elektrical starter. This is the PLUS 12Volt brush.
Soldering new brushes on the elektrical starter. This is the PLUS 12Volt brush.
Dis-assembled elektrical starter. Both brushes are to far gone and need to be replaced. YES, we advice to do an elektrical starter rebuild right now it is to much work to do it later.
Dis-assembled elektrical starter. Both brushes are to far gone and need to be replaced. YES, we advice to do an elektrical starter rebuild right now it is to much work to do it later.
Installed the oil pump after injecting clear 2stroke oil in the oil lines.
Installed the oil pump after injecting clear 2stroke oil in the oil lines.
POV; new check-valves, we removed the bal and spring in the in-line check-valve.
POV; new check-valves, we removed the bal and spring in the in-line check-valve.
Installed the rebuild oil lines. Installed SIX new check-valves.
Installed the rebuild oil lines. Installed SIX new check-valves.
Rebuild oil pump, installed new lever seal, new rotor seal and "head" gasket. After the rebuild we do a bench-check for a first functional check.
Rebuild oil pump, installed new lever seal, new rotor seal and "head" gasket. After the rebuild we do a bench-check for a first functional check.
Cilinder installed on the engine. Pistons all on the right place and position.
Cilinder installed on the engine. Pistons all on the right place and position.
Cilinder installed on the engine. Pistons all on the right place and position.
Prepairing the cilinder before installing it on the engine.
Prepairing the cilinder before installing it on the engine.
Complete blokrevisie Suzuki GT750-K (CV)
YES, the holes for the 2stroke oil are open, there are three holes in the cilinder foot gasket.
YES, the holes for the 2stroke oil are open, there are three holes in the cilinder foot gasket.
YES, the holes for the 2stroke oil are open, there are three holes in the cilinder foot gasket.
Where we repaired the engine cilinder foot surface we added some sealant so the footer gasket can seal better.
Where we repaired the engine cilinder foot surface we added some sealant so the footer gasket can seal better.
Take a look behind the piston, in the past someone used a screw driver on the FALSE place to remove the cilinder. We repaired it with 2k material which is as hard as the aluminum.
Take a look behind the piston, in the past someone used a screw driver on the FALSE place to remove the cilinder. We repaired it with 2k material which is as hard as the aluminum.
All three pistons installed.
All three pistons installed.
All three pistons installed.
LEFT piston close up: pointer has to point in the exhaust direction.
LEFT piston close up: pointer has to point in the exhaust direction.
BE SURE: The circlips have to be installed in the right way. We, at KnalNaarPotz take photo's of everiy installed piston circlip.
BE SURE: The circlips have to be installed in the right way. We, at KnalNaarPotz take photo's of everiy installed piston circlip.
BE SURE: The circlips have to be installed in the right way. We, at KnalNaarPotz take photo's of everiy installed piston circlip.
BE SURE: The circlips have to be installed in the right way. We, at KnalNaarPotz take photo's of everiy installed piston circlip.
BE SURE: The circlips have to be installed in the right way. We, at KnalNaarPotz take photo's of everiy installed piston circlip.
BE SURE: The circlips have to be installed in the right way. We, at KnalNaarPotz take photo's of everiy installed piston circlip.
BE SURE: The circlips have to be installed in the right way. We, at KnalNaarPotz take photo's of everiy installed piston circlip.
RIGHT piston close up: pointer has to point in the exhaust direction.
RIGHT piston close up: pointer has to point in the exhaust direction.
CENTER piston close up: pointer has to point in the exhaust direction.
CENTER piston close up: pointer has to point in the exhaust direction.
Use enough grease for the first run of the engine and of course that NO PARTS fall into the engine at assembling these parts.
Use enough grease for the first run of the engine and of course that NO PARTS fall into the engine at assembling these parts.
Pistons and it's small-end parts.
Pistons and it's small-end parts.
Preparing the M10 cilinder bolts. Notice you have to torque these bolts in TWO sets, 30Nm and 40Nm.
Preparing the M10 cilinder bolts. Notice you have to torque these bolts in TWO sets, 30Nm and 40Nm.
Pistons have to be installed correct and on the right place as measured.
Pistons have to be installed correct and on the right place as measured.
Preparing all the piston parts before installing.
Preparing all the piston parts before installing.
Preparing the cilinder and cilinderhead for installing on the rebuild engine.
Preparing the cilinder and cilinderhead for installing on the rebuild engine.
Routing the cables (in the right way) and SRIS hoses underneath the GT750 engine.
Routing the cables (in the right way) and SRIS hoses underneath the GT750 engine.
Routing the cables (in the right way) and SRIS hoses underneath the GT750 engine.
Routing the cables (in the right way) and SRIS hoses underneath the GT750 engine.
In COLD situation, the thermostat didn't close any more, so the engine will get some temperature problems, of course this engine wouldn't overheat when you used this thermostat.
In COLD situation, the thermostat didn't close any more, so the engine will get some temperature problems, of course this engine wouldn't overheat when you used this thermostat.
CLOSE UP: In COLD situation, the thermostat didn't close any more, so the engine will get some temperature problems, of course this engine wouldn't overheat when you used this thermostat.
CLOSE UP: In COLD situation, the thermostat didn't close any more, so the engine will get some temperature problems, of course this engine wouldn't overheat when you used this thermostat.
SITE UPDATE 27072026: Always cook the thermostat, you need to know if the thermostat can do it's job. In this test the closed thermostat opened but didn't close again. DEFECT.
SITE UPDATE 27072026: Always cook the thermostat, you need to know if the thermostat can do it's job. In this test the closed thermostat opened but didn't close again. DEFECT.
Installed a new ACCENT elektronic ignition.
Installed a new ACCENT elektronic ignition.
All fine now.
All fine now.
Repaired generator cable and connector connection.
Repaired generator cable and connector connection.
Bad generator connection wires, yes you can get a shortcut, so we need to repair it.
Bad generator connection wires, yes you can get a shortcut, so we need to repair it.
Severe sticky generator cable, we can't use it in this way, so we need to clean the cable and install a new cable sheath.
Severe sticky generator cable, we can't use it in this way, so we need to clean the cable and install a new cable sheath.
Installing the generator rotor. M8 bolt torqued with 20Nm.
Installing the generator rotor. M8 bolt torqued with 20Nm.
Installed the spring an spring holders for the kickstarter.
Installed the spring an spring holders for the kickstarter.
Installed the clutch lever (in the right position).
Installed the clutch lever (in the right position).
Installing the clutch parts: Clutch complete installed, bolts torqued with 20Nm en some loctite.
Installing the clutch parts: Clutch complete installed, bolts torqued with 20Nm en some loctite.
Installing the clutch parts: Installing the clutch plates.
Installing the clutch parts: Installing the clutch plates.
Installing the clutch parts: Installing the clutch hub.
Installing the clutch parts: Installing the clutch hub.
Installing the clutch parts: Installing the plate.
Installing the clutch parts: Installing the plate.
Installing the clutch parts: Installing the plain bearing this is an early type GT750 engine.
Installing the clutch parts: Installing the plain bearing this is an early type GT750 engine.
Installing the clutch parts: There is some clutch plate damage on the clutch basket.
Installing the clutch parts: There is some clutch plate damage on the clutch basket.
Installing the clutch parts: There is some clutch plate damage on the clutch basket.
Installing the clutch parts: The clutch basket, someone made the steel ring itself.
Installing the clutch parts: The clutch basket, someone made the steel ring itself.
SITE UPDATE 09072026: Don't forget to install the shim behind the clutch basket. Installing the clutch parts.
SITE UPDATE 09072026: Don't forget to install the shim behind the clutch basket. Installing the clutch parts.
Starter clutch cover installed.
Starter clutch cover installed.
Starter clutch cover installed.
Installed the sprocket retainer plate, installed new O-ring with sealant and new screws.
Installed the sprocket retainer plate, installed new O-ring with sealant and new screws.
Nice engine not finished yet.
Nice engine not finished yet.
Starter clutch side almost completed with all the installed parts.
Starter clutch side almost completed with all the installed parts.
Installing a modified waterpump gear.
Installing a modified waterpump gear.
a starter clutch rebuild kit.
a starter clutch rebuild kit.
Rebuild the starter clutch with.....
Rebuild the starter clutch with.....
Installed new starter clutch bearings, and don't forget the Woodruf key.
Installed new starter clutch bearings, and don't forget the Woodruf key.
Rebuild and cleaned the starterclutch cover.
Rebuild and cleaned the starterclutch cover.
RULER test to check if the crankshaft seals are installed properly.
RULER test to check if the crankshaft seals are installed properly.
RULER test to check if the crankshaft seals are installed properly.
RULER test to check if the crankshaft seals are installed properly.
Before closing the engine ALWAYS do a gear SEQUENCE test to know for sure all gears work fine.
Before closing the engine ALWAYS do a gear SEQUENCE test to know for sure all gears work fine.
"NEW" rebuild crankshaft. We have installed many new parts in this crankshaft.
"NEW" rebuild crankshaft. We have installed many new parts in this crankshaft.
Overview of all the installed engine parts.
Overview of all the installed engine parts.
Don't forget the small O-ring between the engine upper en lower part. Yes when you forget this O-ring it will leak.
Don't forget the small O-ring between the engine upper en lower part. Yes when you forget this O-ring it will leak.
All forks installed in the right way?
All forks installed in the right way?
Don't forget the blind plate for closing the end of the PRIMairy gear shaft.
Don't forget the blind plate for closing the end of the PRIMairy gear shaft.
Check for correct installed rings.
Check for correct installed rings.
SITE UPDATE 07072026: Check for correct installed rings.
SITE UPDATE 07072026: Check for correct installed rings.
Re-assembled gearbox shaft.
Re-assembled gearbox shaft.
Gearbox parts of the secundairy gear shaft.
Gearbox parts of the secundairy gear shaft.
Worn dogs on one of the gears.
Worn dogs on one of the gears.
Hard to see but there were very bad dogs on the gears. We repaired them all on the SECundairy shaft.
Hard to see but there were very bad dogs on the gears. We repaired them all on the SECundairy shaft.
Hard to see but there were very bad dogs on the gears. We repaired them all on the SECundairy shaft.
Hard to see but there were very bad dogs on the gears. We repaired them all on the SECundairy shaft.
Inspecting the dogs on the gears, some were far gone and needed to be repaired. Sadly we can't disassemble the PRIMairy shaft, and we replaced the shaft by another used one.
Inspecting the dogs on the gears, some were far gone and needed to be repaired. Sadly we can't disassemble the PRIMairy shaft, and we replaced the shaft by another used one.
Bad gearbox bearings with a lot of rust and debries.
Bad gearbox bearings with a lot of rust and debries.
A lot of rust in the gearbox bearings. These bearings need to be replaced.
A lot of rust in the gearbox bearings. These bearings need to be replaced.
The second one needs to be installed in the kickstarter shaft.
The second one needs to be installed in the kickstarter shaft.
We have two plugs.
We have two plugs.
This plug is installed on the right place. Sadly very bad bearings on the gearbox shafts.
This plug is installed on the right place. Sadly very bad bearings on the gearbox shafts.
Someone did a very bad job. The PLUG of the kickstarter was installed on the OIL side of the PRIMAIRY gear shaft.
Someone did a very bad job. The PLUG of the kickstarter was installed on the OIL side of the PRIMAIRY gear shaft.
There is something wrong, forgot to repair this srewdriver insert on the sealant surface of the engine.
There is something wrong, forgot to repair this srewdriver insert on the sealant surface of the engine.
Repaired side of the engine, seal for the shifter installed.
Repaired side of the engine, seal for the shifter installed.
Nice and clean engine.
Nice and clean engine.
Nice and clean engine.
Gear shifting drum and shifting forks installed, don't forget the large ring on the right side.
Gear shifting drum and shifting forks installed, don't forget the large ring on the right side.
Close up of the waterpump shaft and the LEAK by-pass hose.
Close up of the waterpump shaft and the LEAK by-pass hose.
Flipped the engine to install the parts which are used to be inside of the engine.
Flipped the engine to install the parts which are used to be inside of the engine.
Closing the waterpump housing.
Closing the waterpump housing.
Installed impeller, almost ready to close the waterpump housing.
Installed impeller, almost ready to close the waterpump housing.
Waterpump installed, always be sure the waterpump is locked in it's position.
Waterpump installed, always be sure the waterpump is locked in it's position.
Installing a NEW waterpump, the shaft of the old waterpump was to far gone tom reuse again. YES this is a new waterpump with a new shaft.
Installing a NEW waterpump, the shaft of the old waterpump was to far gone tom reuse again. YES this is a new waterpump with a new shaft.
Installing a NEW waterpump, the shaft of the old waterpump was to far gone tom reuse again. YES this is a new waterpump with a new shaft.
After all the repair work it's time for cleaning the upper and lower engine cases. We installed the oil plate already in the upper casing.
After all the repair work it's time for cleaning the upper and lower engine cases. We installed the oil plate already in the upper casing.
After all the repair work it's time for cleaning the upper and lower engine cases.
After all the repair work it's time for cleaning the upper and lower engine cases.
Also a defect M6 threading, repaired with a new helicoil.
Also a defect M6 threading, repaired with a new helicoil.
Make new treading to insert a M6 helicoil.
Make new treading to insert a M6 helicoil.
Checking all threading on this engine cases, there were more broken threading on the engine, repaired with several helicoils.
Checking all threading on this engine cases, there were more broken threading on the engine, repaired with several helicoils.
Bad drilled broken bolt and bad installed helicoil, we inserted a new helicoil. When you don't drill out the broken bolts acurate you will have problems with installing parts. As we had on this engine.
Bad drilled broken bolt and bad installed helicoil, we inserted a new helicoil. When you don't drill out the broken bolts acurate you will have problems with installing parts. As we had on this engine.
This engine was damaged by a broken chain. Repaired with some glue, what, of course leaked. We welded the leaking area on both sides.
This engine was damaged by a broken chain. Repaired with some glue, what, of course leaked. We welded the leaking area on both sides.
This engine was damaged by a broken chain. Repaired with some glue, what, of course leaked. We welded the leaking area on both sides.
Repairing a lot of damaged threading on this engine. Also we found hardened steel studs an broken bolts. It was hard to get these out.
Repairing a lot of damaged threading on this engine. Also we found hardened steel studs an broken bolts. It was hard to get these out.
Polishing all the engine parts.
Polishing all the engine parts.
Polishing all the engine parts.
Polishing all the engine parts.
Polishing all the engine parts.
Rebuild oil pump.
Rebuild oil pump.
SITE UPDATE 01072026: Rebuilding the oil pump, new lever shaft seal, new rotor axle seal, new (head)gasket.
SITE UPDATE 01072026: Rebuilding the oil pump, new lever shaft seal, new rotor axle seal, new (head)gasket.
Flipped the oil lines backwards, as you can see within a short time the oil lines getting empty, so the corresponding check-valves are defective. We will rebuild the complete oil lines with new check-valves.
Flipped the oil lines backwards, as you can see within a short time the oil lines getting empty, so the corresponding check-valves are defective. We will rebuild the complete oil lines with new check-valves.
We inject GREEN 2stroke oil in all oil lines this to get a good contrast in the RED oil lines, the contrast in the oil lines shows us in which oil line the oil is leaking through the DEFECT check-valve. In the close-up we can already see that there are problems.
We inject GREEN 2stroke oil in all oil lines this to get a good contrast in the RED oil lines, the contrast in the oil lines shows us in which oil line the oil is leaking through the DEFECT check-valve. In the close-up we can already see that there are problems.
SITE UPDATE 24032026: The oil lines in "hangtest2" a oil line test developed by www.knalnaarpotz.nl, using this kind of position you can do a really good test for the oil lines test.
SITE UPDATE 24032026: The oil lines in "hangtest2" a oil line test developed by www.knalnaarpotz.nl, using this kind of position you can do a really good test for the oil lines test.
Removed the complete clutch and orther parts. TIP: When Phillips head 3 screws are DAMAGED don't use them again.
Removed the complete clutch and orther parts. TIP: When Phillips head 3 screws are DAMAGED don't use them again.
Removing parts inside the engine. Clutch side.
Removing parts inside the engine. Clutch side.
Removing all inside parts from the engine. Ignition and front sprocket side.
Removing all inside parts from the engine. Ignition and front sprocket side.
Removing all inside parts from the engine. Starter clutch side.
Removing all inside parts from the engine. Starter clutch side.
Removing all inside parts from the engine.
Removing all inside parts from the engine.
When disassembling an engine it always looks bad and dirty.
When disassembling an engine it always looks bad and dirty.
Then you need some more force for the last centimeters to remove the cylinder from the engine.
Then you need some more force for the last centimeters to remove the cylinder from the engine.
Then you need some more force for the last centimeters to remove the cylinder from the engine. Yes that "thing" on the floor we have used to remove the cylinder, of course not directly on the cylinder itself.
Then you need some more force for the last centimeters to remove the cylinder from the engine. Yes that "thing" on the floor we have used to remove the cylinder, of course not directly on the cylinder itself.
Then you need some more force for the last centimeters to remove the cylinder from the engine.
Then you need some more force for the last centimeters to remove the cylinder from the engine.
Lifting the engine slowly up on the studs. Sadly there is so much rust between the stud holes and the studs. This will take some hours toremove cylinder of the engine.
Lifting the engine slowly up on the studs. Sadly there is so much rust between the stud holes and the studs. This will take some hours toremove cylinder of the engine.
Lifting the engine slowly up on the studs. Sadly there is so much rust between the stud holes and the studs. This will take some ours to get the cylinder of the engine.
Lifting the engine slowly up on the studs. Sadly there is so much rust between the stud holes and the studs. This will take some ours to get the cylinder of the engine.
Lifting the engine slowly up on the studs. Sadly there is so much rust between the stud holes and the studs. This will take some ours to get the cylinder of the engine.
After removing the cylinder head we have to remove the cylinder: ALWAYS A BIG PROBLEM. As you can see we use large "PREPARED" bolts to lift the cylinder from the bushing at the footer of the engine. This cylinder was stuck rock solid on the studs.
After removing the cylinder head we have to remove the cylinder: ALWAYS A BIG PROBLEM. As you can see we use large "PREPARED" bolts to lift the cylinder from the bushing at the footer of the engine. This cylinder was stuck rock solid on the studs.
Cylinder head revoves, we can see just an easy job to do on this engine.
Cylinder head revoves, we can see just an easy job to do on this engine.
First we removed the M8 and M10 head bolts. The M10 bolts were stuck in the cylinder.
First we removed the M8 and M10 head bolts. The M10 bolts were stuck in the cylinder.
First we removed the M8 and M10 head bolts. The M10 bolts were stuck in the cylinder.
First we removed the M8 and M10 head bolts. The M10 bolts were stuck in the cylinder.
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
SITE UPDATE 22032026: Suzuki GT750-K engine as it arrived at www.knalnaarpotz.nl. We will do a complete rebuild and the engine needs some repairs.
SITE UPDATE 22032026: Suzuki GT750-K engine as it arrived at www.knalnaarpotz.nl. We will do a complete rebuild and the engine needs some repairs.
Complete installed engine on the test stand.
Complete installed engine on the test stand.
Front POV.
Front POV.
SITE UPDATE 27072026: TOTAL GT750 ENGINE REBUILD COMPLETED.
SITE UPDATE 27072026: TOTAL GT750 ENGINE REBUILD COMPLETED.

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