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Wartung und Reparatur Suzuki GT750-A (LdK)

So all work DONE on this Suzuki GT750-A. Let's ride again, it's alive.
So all work DONE on this Suzuki GT750-A. Let's ride again, it's alive.
This SUZUKI GT750-A is complete and up and running again. Engine view.
This SUZUKI GT750-A is complete and up and running again. Engine view.
This SUZUKI GT750-A is complete and up and running again. Engine view.
This SUZUKI GT750-A is complete and up and running again.
This SUZUKI GT750-A is complete and up and running again.
This SUZUKI GT750-A is complete and up and running again.
This SUZUKI GT750-A is complete and up and running again.
Today we finished this bike, we repaired large number of problems, malfunctions, replaced a lot of defect parts and we had to install some missing parts. This SUZUKI GT750-A is complete and up and running again.
Today we finished this bike, we repaired large number of problems, malfunctions, replaced a lot of defect parts and we had to install some missing parts. This SUZUKI GT750-A is complete and up and running again.
A note on the master brake cilinder: The installed master brake cilinder was a wrong one, for ONE disk 14mm. So we had to replace the master brake cilinder by the right one; a D on the bottom and 16mm.
A note on the master brake cilinder: The installed master brake cilinder was a wrong one, for ONE disk 14mm. So we had to replace the master brake cilinder by the right one; a D on the bottom and 16mm.
We thought we spilled a lot of 2stroke oil in the engine during solving the 2stroke oil problems, as we see on the oil stains on the paper cloth it's is not much.
We thought we spilled a lot of 2stroke oil in the engine during solving the 2stroke oil problems, as we see on the oil stains on the paper cloth it's is not much.
Due to all this 2stroke oil problems on the oil pump andoil lines we spilled a lot of 2stroke oil in the engine. So before the "FIRST RUN" we do a DRAIN to blead all 2stroke oil out of the engine.
Due to all this 2stroke oil problems on the oil pump andoil lines we spilled a lot of 2stroke oil in the engine. So before the "FIRST RUN" we do a DRAIN to blead all 2stroke oil out of the engine.
Due to all this 2stroke oil problems on the oil pump andoil lines we spilled a lot of 2stroke oil in the engine. So before the "FIRST RUN" we do a DRAIN to blead all 2stroke oil out of the engine.
Due to all this 2stroke oil problems on the oil pump andoil lines we spilled a lot of 2stroke oil in the engine. So before the "FIRST RUN" we do a DRAIN to blead all 2stroke oil out of the engine.
The new oil lines in the so called "hangtest", just a 95% short and fast test if the oil lines are OK. Ready to be installed.
The new oil lines in the so called "hangtest", just a 95% short and fast test if the oil lines are OK. Ready to be installed.
Fresh and new installed oil lines. The oil lines are filled wit GREEN 2stroke oil to give contrats when the engine is running and the oil pump does it's jopb properly.
Fresh and new installed oil lines. The oil lines are filled wit GREEN 2stroke oil to give contrats when the engine is running and the oil pump does it's jopb properly.
Due to this leaking oil line we have to replace the oil lines AGAIN with another one. So again some extra work because we have to dis-assemble a lot of parts. NOTE, nowadays we see a lot of problems with the oil lines and oil pumps.
Due to this leaking oil line we have to replace the oil lines AGAIN with another one. So again some extra work because we have to dis-assemble a lot of parts. NOTE, nowadays we see a lot of problems with the oil lines and oil pumps.
There is also some 2stroke oil leaking, is there something wrong with the oil line itself? A thorough inspection of the oil lines gives us the problem, the oil line which isn't filled with red oil is leaking at the base of the oil pump.
There is also some 2stroke oil leaking, is there something wrong with the oil line itself? A thorough inspection of the oil lines gives us the problem, the oil line which isn't filled with red oil is leaking at the base of the oil pump.
UPDATE 12-08-2024: We still have some issues with the 2stroke oil distribution. We did a lot of work on the oil lines and the oil pump. AGAIN one of the oil lines give a problem, the oil line bleeds the oil in the engine and fill up with air. What's wrong?
UPDATE 12-08-2024: We still have some issues with the 2stroke oil distribution. We did a lot of work on the oil lines and the oil pump. AGAIN one of the oil lines give a problem, the oil line bleeds the oil in the engine and fill up with air. What's wrong?
It starts looking like an GT750 again. But we have to do some more work on this bike.
It starts looking like an GT750 again. But we have to do some more work on this bike.
It starts looking like an GT750 again. But we have to do some more work on this bike.
Installed the carburettors, which are cleaned thoroughly and then rebuild. We just have to connect the oil pump rod to the oil pump.
Installed the carburettors, which are cleaned thoroughly and then rebuild. We just have to connect the oil pump rod to the oil pump.
Installed the carburettors, which are cleaned thoroughly and then rebuild.
Installed the carburettors, which are cleaned thoroughly and then rebuild.
Found a suitable place fot the newtronic elektronic ignition.
Found a suitable place fot the newtronic elektronic ignition.
Nice new loom Nr2, next thing to do is to connect the loom Nr1.
Nice new loom Nr2, next thing to do is to connect the loom Nr1.
Installed and connected the loom Nr2 on the elektro panel.
Installed and connected the loom Nr2 on the elektro panel.
Some one forgot to install these rubber boots to hold the rear inner fender. We installed two new rubber boots.
Some one forgot to install these rubber boots to hold the rear inner fender. We installed two new rubber boots.
Yes, after we replaced the oil pump too we solved the problem of running red 2stroke oil into the carters of the engine. This is OK now.
Yes, after we replaced the oil pump too we solved the problem of running red 2stroke oil into the carters of the engine. This is OK now.
Do you remember this? Red 2stroke oil was running into the oil lines via the oil pump, so into the carters of the engine. That's not what we want. So we replaced the oil pump by another refurbished one.
Do you remember this? Red 2stroke oil was running into the oil lines via the oil pump, so into the carters of the engine. That's not what we want. So we replaced the oil pump by another refurbished one.
Overview of the Newtronic wiring loom.
Overview of the Newtronic wiring loom.
This is the wiring connection loom of the Newtronic elektronic ignition after a repair, again someone has cut off the wires to the HV coils, WHY? the wiring is plug and play.
This is the wiring connection loom of the Newtronic elektronic ignition after a repair, again someone has cut off the wires to the HV coils, WHY? the wiring is plug and play.
Repaired the wiring on the original voltage regulator, now it's OK for me and for the client.
Repaired the wiring on the original voltage regulator, now it's OK for me and for the client.
In this photo the cut off of more wires in the wiring loon Nr1, also wires cut off on the HV coils, WHY? So we decided to replace both wiring looms by new wiring loom Nr1 and Nr2.
In this photo the cut off of more wires in the wiring loon Nr1, also wires cut off on the HV coils, WHY? So we decided to replace both wiring looms by new wiring loom Nr1 and Nr2.
On the left and below: The orange wire (i think from the factory) had to connections places, although these connections were soldered there was not any isolation around theses connection.
On the left and below: The orange wire (i think from the factory) had to connections places, although these connections were soldered there was not any isolation around theses connection.
I had good eyes for the problems, when i removed all the bad and loose tape around the wiring loom Nr2 i found more problems. See the twisted connection in the GROUND wire, NOPE that won't work for a longer time.
I had good eyes for the problems, when i removed all the bad and loose tape around the wiring loom Nr2 i found more problems. See the twisted connection in the GROUND wire, NOPE that won't work for a longer time.
We needed to re-route wiring loom Nr2, because the airbox would cut off the wires in the wiring loom. I have seen already someone had cut off and did bad repaires on a lot of wires on this GT750. As I removed the wiring loom Nr2 i saw some points on the loom where i thought, there can be a problem.
We needed to re-route wiring loom Nr2, because the airbox would cut off the wires in the wiring loom. I have seen already someone had cut off and did bad repaires on a lot of wires on this GT750. As I removed the wiring loom Nr2 i saw some points on the loom where i thought, there can be a problem.
All installed now, change has the right tension, the rear shock absorbers are installed in the right way now by using smaller rings, so the shock absorber does not hit the frame itself.
All installed now, change has the right tension, the rear shock absorbers are installed in the right way now by using smaller rings, so the shock absorber does not hit the frame itself.
Installed the fornt sprocket: 16 and secured the hex nut with the security ring.
Installed the fornt sprocket: 16 and secured the hex nut with the security ring.
Installed the chain: 106
Installed the chain: 106
Installed the new rear sprocket: 43
Installed the new rear sprocket: 43
We had luck, we had a used spring in stock.
We had luck, we had a used spring in stock.
Do you see it? Someone has forgotten a part (AGAIN) on this GT750. There should be a spring behind the lever of the rear break.
Do you see it? Someone has forgotten a part (AGAIN) on this GT750. There should be a spring behind the lever of the rear break.
Replacing the large seal in the rear wheel, there was a dent in the installed seal and the spacer fell out so the seal was totaly worn.
Replacing the large seal in the rear wheel, there was a dent in the installed seal and the spacer fell out so the seal was totaly worn.
All finished rebuilding the front barke parts.
All finished rebuilding the front barke parts.
Finished rebuilding with all new parts both GT750 calipers.
Finished rebuilding with all new parts both GT750 calipers.
UPDATE 30-08-2024: We found another master brake cylinder (with the letter D at the back) so we will rebuild this one with new parts for this GT750.
UPDATE 30-08-2024: We found another master brake cylinder (with the letter D at the back) so we will rebuild this one with new parts for this GT750.
Overview of the master brake cylinder, which is the wrong one for the 2 disk brakes of the GT750. This is a 14mm master brake cylinder and will not produce enough brake fluid so read: pressure for both disk brakes. Using this master brake cylinder again on this GT750 can be very DANGEROUS! We will see if we can replace the master brake cylinder.
Overview of the master brake cylinder, which is the wrong one for the 2 disk brakes of the GT750. This is a 14mm master brake cylinder and will not produce enough brake fluid so read: pressure for both disk brakes. Using this master brake cylinder again on this GT750 can be very DANGEROUS! We will see if we can replace the master brake cylinder.
Overview of both front brake calipers totaly dis-assembled and thorough cleaned, ready for assembling and install new parts. Take a look at the brake pads, yes they are very worn and need to be replaced.
Overview of both front brake calipers totaly dis-assembled and thorough cleaned, ready for assembling and install new parts. Take a look at the brake pads, yes they are very worn and need to be replaced.
Same problem on the other (right side) of the front brake.
Same problem on the other (right side) of the front brake.
Same problem on the other (right side) of the front brake.
Due te bad maintenance, old brake fluid and no recent use of the brakes causes a lot of corrosion.
Due te bad maintenance, old brake fluid and no recent use of the brakes causes a lot of corrosion.
Did we need to refurbish the front brake calipers? Sure we do, the pistons inside were severe corroded and needs to be replaced. The brake piston is far out, so the brake pads are very worn.
Did we need to refurbish the front brake calipers? Sure we do, the pistons inside were severe corroded and needs to be replaced. The brake piston is far out, so the brake pads are very worn.
The RED circled parts were missing in the master brake cylinder.
The RED circled parts were missing in the master brake cylinder.
What is missing? The "end seat" at the end of the spring isn't installed.
What is missing? The "end seat" at the end of the spring isn't installed.
Dis-assembling the master brake cilinder for a rebuild; Again we found missing parts, also this master brake cylinder is NOT suitable for the 2 disk brakes of the GT750. This is a 14mm type master brake cylinder.
Dis-assembling the master brake cilinder for a rebuild; Again we found missing parts, also this master brake cylinder is NOT suitable for the 2 disk brakes of the GT750. This is a 14mm type master brake cylinder.
This GT750 also needed new sprockets and chain so we will install the front sprocket 16, rear sprocket 43 and a O-ring chain with length of 106.
This GT750 also needed new sprockets and chain so we will install the front sprocket 16, rear sprocket 43 and a O-ring chain with length of 106.
This GT750 also needed new sprockets and chain so we will install the front sprocket 16, rear sprocket 43 and a O-ring chain with length of 106.
By the way, look and the brake master cylinder, the oil cup is dark colored, so there was very old brake fluid in it. The front brake was very bad.
By the way, look and the brake master cylinder, the oil cup is dark colored, so there was very old brake fluid in it. The front brake was very bad.
Bad brakes? Sure, you can pull the brake lever to the grip. Take a look at the brake fluid cup, the brake fluid is to dark for recent brake fluid. So we need to refurbush/renew the whole brake system.
Bad brakes? Sure, you can pull the brake lever to the grip. Take a look at the brake fluid cup, the brake fluid is to dark for recent brake fluid. So we need to refurbush/renew the whole brake system.
We also replaced the hoses on the radiator sub tank, because of an old hose (upper) and a wrong hose (lower)
We also replaced the hoses on the radiator sub tank, because of an old hose (upper) and a wrong hose (lower)
These coolant hose isn't installed correct the hose clamps are fitted on one ring of the hose clamp. We repaired this with all new parts, this because it's possible that it will break down.
These coolant hose isn't installed correct the hose clamps are fitted on one ring of the hose clamp. We repaired this with all new parts, this because it's possible that it will break down.
Someone cut off a part of the brake hose mounting, we installed a new part and corrected the installation of the brake hose.
Someone cut off a part of the brake hose mounting, we installed a new part and corrected the installation of the brake hose.
Replaced the the oil lines and filled up with green 2styroke oil, this because we have red 2stroke oil in the oil tank. We will wait and see if we get the problem again.
Replaced the the oil lines and filled up with green 2styroke oil, this because we have red 2stroke oil in the oil tank. We will wait and see if we get the problem again.
Replaced the oil lines for "new" refurbished and tested oil lines. Sadly this is a lot of work because you have to remove the elektrical starter etc.
Replaced the oil lines for "new" refurbished and tested oil lines. Sadly this is a lot of work because you have to remove the elektrical starter etc.
Red oil is running on to the cylinders, that is really wrong. It is possible that the oil runs into the carters of the engine. Take a look at the oil pump lever, this is a lever for a cable movement, as this is a GT750-A it has a rod! BUT: How do you adjust the rod to the markings, as you have tio adjust the J-K models on a much different way
Red oil is running on to the cylinders, that is really wrong. It is possible that the oil runs into the carters of the engine. Take a look at the oil pump lever, this is a lever for a cable movement, as this is a GT750-A it has a rod! BUT: How do you adjust the rod to the markings, as you have tio adjust the J-K models on a much different way
UPDATE 24-08-2024: ALWAYS pay attention to everything on what you are working on. We noticed something strange on the oil lines! For the oil pump test we fill up the oil lines with another colored oil of what is in the oil tank. The different colored oil SHOULD NOT run away AFTER the oil pump. So here is something wrong.
UPDATE 24-08-2024: ALWAYS pay attention to everything on what you are working on. We noticed something strange on the oil lines! For the oil pump test we fill up the oil lines with another colored oil of what is in the oil tank. The different colored oil SHOULD NOT run away AFTER the oil pump. So here is something wrong.
Cleaned carburettor unit, almost ready for use, the hoses will be installed later.
Cleaned carburettor unit, almost ready for use, the hoses will be installed later.
Cleaned carburettor unit, almost ready for use, the hoses will be installed later.
Cleaned carburettor unit, almost ready for use, the hoses will be installed later.
Cleaned carburettor unit, almost ready for use, the hoses will be installed later.
RIGHT and CENTER carburettor: Thorough cleaning before using; Center carburettor has been cleaned already.
RIGHT and CENTER carburettor: Thorough cleaning before using; Center carburettor has been cleaned already.
RIGHT and CENTER carburettor: Thorough cleaning before using; Center carburettor has been cleaned already.
Broken M6 bolt for connecting the carburettors on the rail. Repaired by drilling and inserting a M6 heli-coil. In total we inserted 11 heli-coils!
Broken M6 bolt for connecting the carburettors on the rail. Repaired by drilling and inserting a M6 heli-coil. In total we inserted 11 heli-coils!
Heli-coil threading M4 in the float bowl seat.
Heli-coil threading M4 in the float bowl seat.
Heli-coil threading M4 in the float bowl seat.
All green marked threading holes needed a new heli-coil for repair.
All green marked threading holes needed a new heli-coil for repair.
All green marked threading holes needed a new heli-coil for repair.
Again, not our job: Als0 a bad installed heli-coil, we removed several heli-coils and installed new ones.
Again, not our job: Als0 a bad installed heli-coil, we removed several heli-coils and installed new ones.
This is why all the float bowls were leaking, bad installed or bad threaded float bowl screws. The inserted heli-coil is not deep enough so the float bwol won't close on the gasket properly. We needed to repair ALL M4 threading in the float bowl seat.
This is why all the float bowls were leaking, bad installed or bad threaded float bowl screws. The inserted heli-coil is not deep enough so the float bwol won't close on the gasket properly. We needed to repair ALL M4 threading in the float bowl seat.
All the float bowls are braun due to leaking gas, why? Do you wonder?
All the float bowls are braun due to leaking gas, why? Do you wonder?
Some of the carburettor parts disassembled. We collect all the parts PER carburettor, so all parts will go to it's own carburettor, so for Left, Center and Right.
Some of the carburettor parts disassembled. We collect all the parts PER carburettor, so all parts will go to it's own carburettor, so for Left, Center and Right.
The carburettor body parts disassembled.
The carburettor body parts disassembled.
A new rebuild engine needs clean and functioning carburettors. So we disassembled all three carburettors for cleaning and rebuilding.
A new rebuild engine needs clean and functioning carburettors. So we disassembled all three carburettors for cleaning and rebuilding.
On this bike we have to do our job always TWICE, we discover always another problem (again), and we have to correct the found problem. On this photo we wondered why we can't install the brake pedal cap with the pin. The swinging arm shaft was installed from the wrong side. So we needed to correct this before we could install the brake pedal and it's parts.
On this bike we have to do our job always TWICE, we discover always another problem (again), and we have to correct the found problem. On this photo we wondered why we can't install the brake pedal cap with the pin. The swinging arm shaft was installed from the wrong side. So we needed to correct this before we could install the brake pedal and it's parts.
And we go on: GT750 engine "married" again in it's frame, we can do our work on this bike. Sadly this bike needs a lot of a mechanics attention.
And we go on: GT750 engine "married" again in it's frame, we can do our work on this bike. Sadly this bike needs a lot of a mechanics attention.
And we go on: GT750 engine "married" again in it's frame, we can do our work on this bike. Sadly this bike needs a lot of a mechanics attention.
And we go on: GT750 engine "married" again in it's frame, we can do our work on this bike. Sadly this bike needs a lot of a mechanics attention.
UPDATE 21-08-2024: And we go on: GT750 engine "married" again in it's frame, we can do our work on this bike. Sadly this bike needs a lot of a mechanics attention.
UPDATE 21-08-2024: And we go on: GT750 engine "married" again in it's frame, we can do our work on this bike. Sadly this bike needs a lot of a mechanics attention.
Finished the total rebuild of this GT750-A engine.
Finished the total rebuild of this GT750-A engine.
Finished the total rebuild of this GT750-A engine.
Finished the total rebuild of this GT750-A engine.
Finished the total rebuild of this GT750-A engine.
Finished the total rebuild of this GT750-A engine.
Finished the total rebuild of this GT750-A engine.
Some close-ups of the finished total rebuild of this GT750-A engine.
Some close-ups of the finished total rebuild of this GT750-A engine.
Some close-ups of the finished total rebuild of this GT750-A engine.
Some close-ups of the finished total rebuild of this GT750-A engine.
Always check and double check the O-rings for the coolant canals in the barrel.
Always check and double check the O-rings for the coolant canals in the barrel.
Check and double check if the OIL holes in the footer gasket are open! You have three holes to check.
Check and double check if the OIL holes in the footer gasket are open! You have three holes to check.
Check if you have installed the pistoins on the right place, this because LEFT is the RIGHT piston to install.
Check if you have installed the pistoins on the right place, this because LEFT is the RIGHT piston to install.
Small-end bearing and thrust washer with enough grease installed.
Small-end bearing and thrust washer with enough grease installed.
Always check if the GENUINE piston circlips are installed in the right way, they have to be in it's seat.
Always check if the GENUINE piston circlips are installed in the right way, they have to be in it's seat.
Preparing the stainless steel head bolts. All the headbolts should be torqued in the right sequence with the right torque value.
Preparing the stainless steel head bolts. All the headbolts should be torqued in the right sequence with the right torque value.
Preparing all three pistons before installing the on the cranckshaft.
Preparing all three pistons before installing the on the cranckshaft.
I noticed that all the barrels need to be repaired, threading M8 holes and sometimes install new SRIS hose connections.
I noticed that all the barrels need to be repaired, threading M8 holes and sometimes install new SRIS hose connections.
Prepairing the cilinder head before installeng by cleaning the cilinderhead and installing the TESTED (passed) thermostat. The thermostat housing is installed with a new gasket and on both side some sealant.
Prepairing the cilinder head before installeng by cleaning the cilinderhead and installing the TESTED (passed) thermostat. The thermostat housing is installed with a new gasket and on both side some sealant.
Installed oil pump, passed after the bench check. Will be tested again with our running test procedure sequence.
Installed oil pump, passed after the bench check. Will be tested again with our running test procedure sequence.
There is always something with elektrical starters, cleaning was needed and the replacement of the PLUS connection brush.
There is always something with elektrical starters, cleaning was needed and the replacement of the PLUS connection brush.
Installing the plus 12Volt connection brush.
Installing the plus 12Volt connection brush.
Oil lines installed after a thorough test and the replacement of the two MID cilinder check-valves. These defect check-valves were the cause of the severe damage on this GT750 engine.
Oil lines installed after a thorough test and the replacement of the two MID cilinder check-valves. These defect check-valves were the cause of the severe damage on this GT750 engine.
Installing the stator of the generator.
Installing the stator of the generator.
Installing the rotor for the generator.
Installing the rotor for the generator.
Completed clutch cover for the engine.
Completed clutch cover for the engine.
Installing the kickstarter with ALL of the parts for that! Do you remember the missing parts on earlier photo's?
Installing the kickstarter with ALL of the parts for that! Do you remember the missing parts on earlier photo's?
Complete installed clutch.
Complete installed clutch.
Never go for cheap and use your old clutch plates again. The new clutch plates aren't expensive in comparisson of the work you have to do.
Never go for cheap and use your old clutch plates again. The new clutch plates aren't expensive in comparisson of the work you have to do.
Almost a completed clutch.
Almost a completed clutch.
Clutch basket install.
Clutch basket install.
Installing the clutch parts. First a shim, tha the special formed plate.
Installing the clutch parts. First a shim, tha the special formed plate.
Finished engine cover LEFT side.
Finished engine cover LEFT side.
Of course on an engine rebuild you need to replace these bearings. when they are bad you will have some problems with adjusting your ignition.
Of course on an engine rebuild you need to replace these bearings. when they are bad you will have some problems with adjusting your ignition.
Installing the parts on the ignition side of the engine.
Installing the parts on the ignition side of the engine.
Torquing the engine bolts in the right order and the right value.
Torquing the engine bolts in the right order and the right value.
DON't forget this ;ittle O-ring before closing the engine.
DON't forget this ;ittle O-ring before closing the engine.
Side view RIGHT of the engine.
Side view RIGHT of the engine.
Side view LEFT of the engine.
Side view LEFT of the engine.
Don't forget the bearing blank plate.
Don't forget the bearing blank plate.
Overview of the rebuild engine and it's parts. Some of the gears had to be repaired to due to wrong repair.
Overview of the rebuild engine and it's parts. Some of the gears had to be repaired to due to wrong repair.
Checking the this cranckshaft seal if it is in it's right position and if it's running free of the cranckshaft.
Checking the this cranckshaft seal if it is in it's right position and if it's running free of the cranckshaft.
Checking the this cranckshaft seal if it is in it's right position and if it's running free of the cranckshaft.
Checking the this cranckshaft seal if it is in it's right position and if it's running free of the cranckshaft.
Checking the this cranckshaft seal if it is in it's right position and if it's running free of the cranckshaft.
Checking the this cranckshaft seal if it is in it's right position and if it's running free of the cranckshaft.
Checking the RIGHT cranckshaft seal if it is in it's right position.
Checking the RIGHT cranckshaft seal if it is in it's right position.
Checking the LEFT cranckshaft seal if it is in it's right position.
Checking the LEFT cranckshaft seal if it is in it's right position.
Inspection the right position of the slotted cranckshaft seal.
Inspection the right position of the slotted cranckshaft seal.
Installing the rebuild cranckshaft.
Installing the rebuild cranckshaft.
That's why we know, the positioning pin wasn't in it's bushing hole, so you can make al lot of force when you screw in and torque the engine bolts.
That's why we know, the positioning pin wasn't in it's bushing hole, so you can make al lot of force when you screw in and torque the engine bolts.
When you are NOT PRECISE, stop working on engines, the positioning pin is pressed inside it's hole due to BAD install of the kickstater shaft. How do we know??
When you are NOT PRECISE, stop working on engines, the positioning pin is pressed inside it's hole due to BAD install of the kickstater shaft. How do we know??
Waterpump installed.
Waterpump installed.
Installing the refurbished waterpump in it's engine housing.
Installing the refurbished waterpump in it's engine housing.
Cleaning the very dirty GT750 engine. TO MUCH sealant.
Cleaning the very dirty GT750 engine. TO MUCH sealant.
Cleaning the very dirty GT750 engine.
Cleaning the very dirty GT750 engine.
When you use a standard thread nut on a M10x1,25 threading you will damage the thread oin this stud. So we needed to repair this stud by making new thread.
When you use a standard thread nut on a M10x1,25 threading you will damage the thread oin this stud. So we needed to repair this stud by making new thread.
Completed SECUNDAIRE gear shaft of the GT750 engine.
Completed SECUNDAIRE gear shaft of the GT750 engine.
Close up of the repaired gear dogs.
Close up of the repaired gear dogs.
We repaired the dogs on the 3rd gear.
We repaired the dogs on the 3rd gear.
The gear dogs need to be repaired.
The gear dogs need to be repaired.
Close up of the bad dogs on the gears.
Close up of the bad dogs on the gears.
Bad repaired dogs on the gears. We have to repair the dogs on the gears again.
Bad repaired dogs on the gears. We have to repair the dogs on the gears again.
Bad repaired gears. This gear we have to replade. NOTICE the rusty small bearing on the back ground, so we found the gears inside the GT750 engine.
Bad repaired gears. This gear we have to replade. NOTICE the rusty small bearing on the back ground, so we found the gears inside the GT750 engine.
Removing the old and bad bearings. NOTICE the rusty small bearing on the back ground, so we found the gears inside the GT750 engine.
Removing the old and bad bearings. NOTICE the rusty small bearing on the back ground, so we found the gears inside the GT750 engine.
Polished engine parts for the GT750-A. Very satisfying to see these shiny parts.
Polished engine parts for the GT750-A. Very satisfying to see these shiny parts.
Polished engine parts for the GT750-A. Very satisfying to see these shiny parts.
Preparing engine parts before polishing.
Preparing engine parts before polishing.
Preparing engine parts before polishing.
Preparing engine parts before polishing.
This threading hole needs a M8 helicoil.
This threading hole needs a M8 helicoil.
How do the do it? The threading is M8, if this threading is going bad, use a helicoil. Nope some persons drill the holes so big that we needed to make a bushing with M12 to repare this large hole.
How do the do it? The threading is M8, if this threading is going bad, use a helicoil. Nope some persons drill the holes so big that we needed to make a bushing with M12 to repare this large hole.
Something went wrong with boring the barrel which came on the engine. It looks like the cilinder walls are hardened due to the narrow bore. This means we needed another barrel for the rebore. So polishing and reparing this (nice) barrel. This barrel is polished already.
Something went wrong with boring the barrel which came on the engine. It looks like the cilinder walls are hardened due to the narrow bore. This means we needed another barrel for the rebore. So polishing and reparing this (nice) barrel. This barrel is polished already.
Something went wrong with boring the barrel which came on the engine. It looks like the cilinder walls are hardened due to the narrow bore. This means we needed another barrel for the rebore. So polishing and reparing this (nice) barrel.
Something went wrong with boring the barrel which came on the engine. It looks like the cilinder walls are hardened due to the narrow bore. This means we needed another barrel for the rebore. So polishing and reparing this (nice) barrel.
Assembled waterpump.
Assembled waterpump.
Assembled waterpump.
Rebuilding the waterpomp. As nowadays the mechanical seal breaks down we replace this part by a new one. Also we install a new seal and a new bearing.
Rebuilding the waterpomp. As nowadays the mechanical seal breaks down we replace this part by a new one. Also we install a new seal and a new bearing.
Cleaned and polished parts and new parts for the waterpump.
Cleaned and polished parts and new parts for the waterpump.
<SITE UPDATE 13-05-2024/ Rebuilding the waterpomp. Showing here all new parts. The housing for the waterpump needs to be cleaned and polisher thoroughly.
<SITE UPDATE 13-05-2024/ Rebuilding the waterpomp. Showing here all new parts. The housing for the waterpump needs to be cleaned and polisher thoroughly.
Wrong coolant used in this engine. A lot of corrosion on all the parts of the waterpump.
Wrong coolant used in this engine. A lot of corrosion on all the parts of the waterpump.
No skew available, this will be another job to do.
No skew available, this will be another job to do.
The dogs have to be slightly skewed, so the dogs will grab eachother and fix the gears.
The dogs have to be slightly skewed, so the dogs will grab eachother and fix the gears.
Not good.......
Not good.......
Someone did a bad job on the gears. It's for sure this gears will give problems after shifting.
Someone did a bad job on the gears. It's for sure this gears will give problems after shifting.
Always inspect the gears on the secundairy shaft. 3rd gear is the most common gear with bad "dogs". Doesn't look good on the gear shaft.
Always inspect the gears on the secundairy shaft. 3rd gear is the most common gear with bad "dogs". Doesn't look good on the gear shaft.
Another view angle to inspect the right rod.
Another view angle to inspect the right rod.
Checking the RIGHT ROD with a square, it indeed looks if the rod is bend. The gap below is smaller than the gap on to of the rod. So the rod is bend!
Checking the RIGHT ROD with a square, it indeed looks if the rod is bend. The gap below is smaller than the gap on to of the rod. So the rod is bend!
Some people have eyes for discovering problems, it looks if this RIGHT ROD is bend too. So we need further inspections.
Some people have eyes for discovering problems, it looks if this RIGHT ROD is bend too. So we need further inspections.
LEFT ROD, this rod looks good.
LEFT ROD, this rod looks good.
Insecting the CENTER ROD, it's clear that this one is bend and needs to be replaced.
Insecting the CENTER ROD, it's clear that this one is bend and needs to be replaced.
This is wrong on the cranckshaft; BAD REBUILD, the bearing right near the gear should be a sloted and grooved bearing.
This is wrong on the cranckshaft; BAD REBUILD, the bearing right near the gear should be a sloted and grooved bearing.
Take a good look on the cranckshaft, WHAT's WRONG?
Take a good look on the cranckshaft, WHAT's WRONG?
And now we know for sure there was a cranckshaft rebuild in the past.
And now we know for sure there was a cranckshaft rebuild in the past.
Oil plate in the upper engine casing, also a lot of rust.
Oil plate in the upper engine casing, also a lot of rust.
<SITE UPDATE 04-04-2024/ What happened here? A bearing covered in rust. Yes we know that this GT750 wasn't used a long time.
<SITE UPDATE 04-04-2024/ What happened here? A bearing covered in rust. Yes we know that this GT750 wasn't used a long time.
Someone has forgotten something. I'm sure there were engine parts left over after closing the engine.
Someone has forgotten something. I'm sure there were engine parts left over after closing the engine.
Rubber ring placed up side down.
Rubber ring placed up side down.
Wrong ring on the electrical starter gear.
Wrong ring on the electrical starter gear.
Removed studs.
Removed studs.
Removing the studs, so we can repair the short barrel footer stud. And of course we will replace the studs on the right place.
Removing the studs, so we can repair the short barrel footer stud. And of course we will replace the studs on the right place.
Take a look at the short barrel footer stud, totaly damaged. How? When you screw on a M10 standard nut on a M10 metric fine thread you will damage the thread of the stud. This means that the mechanic who worked before on this engine didn't know anything about the difference between threading.
Take a look at the short barrel footer stud, totaly damaged. How? When you screw on a M10 standard nut on a M10 metric fine thread you will damage the thread of the stud. This means that the mechanic who worked before on this engine didn't know anything about the difference between threading.
Take a look at the short barrel footer stud, totaly damaged.
Take a look at the short barrel footer stud, totaly damaged.
Again not our job, when you remove the barrel studs (why?) you have to install the studs on the right place again. The stud with the barrel location thickening should be in the front stud row outer right.
Again not our job, when you remove the barrel studs (why?) you have to install the studs on the right place again. The stud with the barrel location thickening should be in the front stud row outer right.
Not our job, when you remove the barrel studs (why?) you have to install the studs on the right place again. The stud with the barrel location thickening should be in the front stud row outer left.
Not our job, when you remove the barrel studs (why?) you have to install the studs on the right place again. The stud with the barrel location thickening should be in the front stud row outer left.
<SITE UPDATE 04-04-2024/ 01 Explanation.
<SITE UPDATE 04-04-2024/ 01 Explanation.
Removed the LEFT en CENTER piston for inspection.
Removed the LEFT en CENTER piston for inspection.
Clear to see: A bend piston rod.
Clear to see: A bend piston rod.
On this photo hardly visable, but you can see a bend piston rod.
On this photo hardly visable, but you can see a bend piston rod.
Severe damage cilinder. As our cilinder and cranckshaft specialist says, the bore was to narrow!
Severe damage cilinder. As our cilinder and cranckshaft specialist says, the bore was to narrow!
Severe cracked piston. After removing the psiton pin the piston fell into peaces.
Severe cracked piston. After removing the psiton pin the piston fell into peaces.
Severe cracked piston.
Severe cracked piston.
Severe cracked piston.
Before the complete barrel was removed from the engine you could see that the center piston was severe cracked.
Before the complete barrel was removed from the engine you could see that the center piston was severe cracked.
Had to use extremely extended force to remove the barrel in total.
Had to use extremely extended force to remove the barrel in total.
The barrel was stuck on the center piston, with my barrel puller bolts i could NOT pull the whole barrel.
The barrel was stuck on the center piston, with my barrel puller bolts i could NOT pull the whole barrel.
With the barrel installed you can clearly see the cracked center piston.
With the barrel installed you can clearly see the cracked center piston.
Standard bore = 70mm.
Standard bore = 70mm.
Standard bore an damaged cilinder.
Standard bore an damaged cilinder.
GT750-A engine on the workbench for disassembling.
GT750-A engine on the workbench for disassembling.
Removed the engine today for inspection and repair of the severe engine damage.
Removed the engine today for inspection and repair of the severe engine damage.
When a check-valve is defect, a filled oil line will bleed the oil in the hangtest immediately. The not oil filled oil line is clear visable.
When a check-valve is defect, a filled oil line will bleed the oil in the hangtest immediately. The not oil filled oil line is clear visable.
Inspecting and testing the oil lines by the hangtest, one check-valve of the center cilinder is defect, as you can see on an empty oil line. This is the main reason of the hydraulic lock on the center cilinder.
Inspecting and testing the oil lines by the hangtest, one check-valve of the center cilinder is defect, as you can see on an empty oil line. This is the main reason of the hydraulic lock on the center cilinder.
Disassembling the GT750-A for removing the engine (2 man lift). Also testing the petcock for leaking in NORMAL position.
Disassembling the GT750-A for removing the engine (2 man lift). Also testing the petcock for leaking in NORMAL position.
Disassembling the GT750-A for removing the engine (2 man lift).
Disassembling the GT750-A for removing the engine (2 man lift).
Disassembling the GT750-A for removing the engine (2 man lift).
Disassembling the GT750-A for removing the engine (2 man lift).
Disassembling the GT750-A for removing the engine (2 man lift).
I think this is a lot of "2stroke" oil drained from the center cilinder. i have collected this oil into an empty oil cannister: RESULT 0,5liter oil. "2stroke"oil? It's certainly NOT 2stroke oil, but normal engine oil, the oil is to thick to be 2stroke oil.
I think this is a lot of "2stroke" oil drained from the center cilinder. i have collected this oil into an empty oil cannister: RESULT 0,5liter oil. "2stroke"oil? It's certainly NOT 2stroke oil, but normal engine oil, the oil is to thick to be 2stroke oil.
Draining the engine carters by removing the SRIS valves, the center cilinder was filled with almost 0,45liter "2stroke" oil. It took 1/4 of an hour to stop running or dripping.
Draining the engine carters by removing the SRIS valves, the center cilinder was filled with almost 0,45liter "2stroke" oil. It took 1/4 of an hour to stop running or dripping.
Draining the engine carters by removing the SRIS valves, the center cilinder was filled with almost 0,45liter "2stroke" oil.
Draining the engine carters by removing the SRIS valves, the center cilinder was filled with almost 0,45liter "2stroke" oil.
Endoscoping the barrel, found a big problem on the CENTER piston, scratched cilinder wall.
Endoscoping the barrel, found a big problem on the CENTER piston, scratched cilinder wall.
Endoscoping the barrel, found a big problem on the CENTER piston, scratched cilinder wall.
Endoscoping the barrel, found a big problem on the CENTER piston, scratched cilinder wall.
Endoscoping the barrel, found a big problem on the CENTER piston, scratched cilinder wall.
Endoscoping the barrel, found a big problem on the CENTER piston, totaly cracked! This barrel need a rebuild. But WHAT caused this severe PISTON CRACK? We made a conclusion: HYDRAULIC LOCK.
Endoscoping the barrel, found a big problem on the CENTER piston, totaly cracked! This barrel need a rebuild. But WHAT caused this severe PISTON CRACK? We made a conclusion: HYDRAULIC LOCK.
Something is missing, almost 1,5liter coolant is missing. Zoom in on the bucket.
Something is missing, almost 1,5liter coolant is missing. Zoom in on the bucket.
Removed the NEW Delkevic exhausts, draining the coolant from the cooling system.
Removed the NEW Delkevic exhausts, draining the coolant from the cooling system.
Removed the NEW Delkevic exhausts, draining the coolant from the cooling system.
Starting to disassembling parts on the GT750-A.
Starting to disassembling parts on the GT750-A.
Starting to disassembling parts on the GT750-A.
Maintenance and repair of this nice Suzuki GT750-A. Noticed problems: Kickstarter doesn't turn engine, smoking battery connection wires, engine run's bad (OR WON'T RUN).
Maintenance and repair of this nice Suzuki GT750-A. Noticed problems: Kickstarter doesn't turn engine, smoking battery connection wires, engine run's bad (OR WON'T RUN).
Maintenance and repair of this nice Suzuki GT750-A. Noticed problems: Kickstarter doesn't turn engine, smoking battery connection wires, engine run's bad.
Maintenance and repair of this nice Suzuki GT750-A. Noticed problems: Kickstarter doesn't turn engine, smoking battery connection wires, engine run's bad.

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