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Onderhoud na blokrevisie en reparaties Suzuki GT750-A (WL)

We have GREEN 2stroke oil injected in the oil lines, in the oil tank there is red 2stroke oil. When you do the oil pump test the oil lines will be filled with red 2stroke oil which is clearly visable then.
We have GREEN 2stroke oil injected in the oil lines, in the oil tank there is red 2stroke oil. When you do the oil pump test the oil lines will be filled with red 2stroke oil which is clearly visable then.
Re-installing all the parts and fished this part of the job.
Re-installing all the parts and fished this part of the job.
The 2stroke oil lines installed. Another point of view.
The 2stroke oil lines installed. Another point of view.
The 2stroke oil lines installed.
The 2stroke oil lines installed.
The leaking 2stroke oil lines, when KnalNaarPotz did the rebuild some time ago we checked the 2stroke oil lines by doing the hangtests. Sadly we can not check the 2stroke oil lines when the oil pump makes some pressure on the oil lines.
The leaking 2stroke oil lines, when KnalNaarPotz did the rebuild some time ago we checked the 2stroke oil lines by doing the hangtests. Sadly we can not check the 2stroke oil lines when the oil pump makes some pressure on the oil lines.
The fresh and new rebuild 2stroke oil lines with six new check-valves ready to be installed.
The fresh and new rebuild 2stroke oil lines with six new check-valves ready to be installed.
Cleaning the electrical starter bay on the Gt750 engine.
Cleaning the electrical starter bay on the Gt750 engine.
Draining all the coolant from the coolings system, removing all the parts beneath the starter engine cover
Draining all the coolant from the coolings system, removing all the parts beneath the starter engine cover
Removing the airbox and the carburetors (again).
Removing the airbox and the carburetors (again).
SITE UPDATE 20102025: On some complaints of the GT750 owner about leaking oil on the engine we notice that there was an 2stroke OIL leakage on the right hand side of the engine. We found some RED oil on the floor at the parking place of the GT750. The only way to repair this is to replace the complete oil lines by a fresh rebuild one. Sadly this is a lot of work you have to remove a lot of parts.
SITE UPDATE 20102025: On some complaints of the GT750 owner about leaking oil on the engine we notice that there was an 2stroke OIL leakage on the right hand side of the engine. We found some RED oil on the floor at the parking place of the GT750. The only way to repair this is to replace the complete oil lines by a fresh rebuild one. Sadly this is a lot of work you have to remove a lot of parts.
When the fuel tank is DE-rusted and sealed we can send this beautiful Suzuki GT750-A back to it's owner.
When the fuel tank is DE-rusted and sealed we can send this beautiful Suzuki GT750-A back to it's owner.
Of course we want to take a look in the petrol tank, so we used a boroscope to do that. Yes we see a lot of rust.
Of course we want to take a look in the petrol tank, so we used a boroscope to do that. Yes we see a lot of rust.
A cleaner part of the fuel tank.
A cleaner part of the fuel tank.
Of course we want to take a look in the petrol tank, so we used a boroscope to do that. Yes we see a lot of rust.
Of course we want to take a look in the petrol tank, so we used a boroscope to do that. Yes we see a lot of rust.
This is a lot of rust............ Of course we will DE-rust the petrol tank and seal the tank after thta.
This is a lot of rust............ Of course we will DE-rust the petrol tank and seal the tank after thta.
As we have seen that the petrol tank was severe filled with rust, not much rust came trough the fuel cock in the coffee filter.
As we have seen that the petrol tank was severe filled with rust, not much rust came trough the fuel cock in the coffee filter.
After checking the cylinders we drained the petrol tank. It was top filled so it took some time.
After checking the cylinders we drained the petrol tank. It was top filled so it took some time.
RIGHT: Today we checked the cylinder if there is damage due to the amount of rust. Luckily the client didn't use the bike anymore after he discoverd the problems. All looks fine.
RIGHT: Today we checked the cylinder if there is damage due to the amount of rust. Luckily the client didn't use the bike anymore after he discoverd the problems. All looks fine.
CENTER: Today we checked the cylinder if there is damage due to the amount of rust. Luckily the client didn't use the bike anymore after he discoverd the problems. All looks fine.
CENTER: Today we checked the cylinder if there is damage due to the amount of rust. Luckily the client didn't use the bike anymore after he discoverd the problems. All looks fine.
SITE UPDATE 03092025: LEFT: Today we checked the cylinder if there is damage due to the amount of rust. Luckily the client didn't use the bike anymore after he discoverd the problems. All looks fine.
SITE UPDATE 03092025: LEFT: Today we checked the cylinder if there is damage due to the amount of rust. Luckily the client didn't use the bike anymore after he discoverd the problems. All looks fine.
NO NO NO, DO NOT install the oil hose like this! Suzuki wrote a service bullitin about oil startvation. You can see that this 2stroke oil hose, from 2stroke oil tank to the oil pump is pressed between the head of the bolt and the breathing hole of the engine. Of course the 2stroke oil hose will be closed and the engine don't get the 2stroke oil what is needed.
NO NO NO, DO NOT install the oil hose like this! Suzuki wrote a service bullitin about oil startvation. You can see that this 2stroke oil hose, from 2stroke oil tank to the oil pump is pressed between the head of the bolt and the breathing hole of the engine. Of course the 2stroke oil hose will be closed and the engine don't get the 2stroke oil what is needed.
When you touch the fueltap this will leak between the washer and the fuel tank itself. The client has used washers on the bolts, you don't need washers, the aluminum is soft and will not leak.
When you touch the fueltap this will leak between the washer and the fuel tank itself. The client has used washers on the bolts, you don't need washers, the aluminum is soft and will not leak.
MAINTENANCE: Checking the markings of the oil pump, the lever of the oil pump needs to be adjusted. REMEMBER: The oil pump lever is to switch the oil pump ON or OFF, the REVS of the engine will regulate the amount of oil in the cylinder.
MAINTENANCE: Checking the markings of the oil pump, the lever of the oil pump needs to be adjusted. REMEMBER: The oil pump lever is to switch the oil pump ON or OFF, the REVS of the engine will regulate the amount of oil in the cylinder.
Timing dial gauge close up, the black markings give the distance BEFORE TDC (NL=BDP)
Timing dial gauge close up, the black markings give the distance BEFORE TDC (NL=BDP)
We always use a dial gauge to adjust the ignition timing on the engine of the GT750.
We always use a dial gauge to adjust the ignition timing on the engine of the GT750.
MAINTENANCE: Checking the ignition points, we have re-adjusted the points. We also changed the position of the felt for lubricating the ingnition cam.
MAINTENANCE: Checking the ignition points, we have re-adjusted the points. We also changed the position of the felt for lubricating the ingnition cam.
MAINTENANCE: The cylinderhead is torqued at 40Nm, after some 200km you have to retorque all the bolts on the cylinderhead again, on 40Nm, and yes it was necessary.
MAINTENANCE: The cylinderhead is torqued at 40Nm, after some 200km you have to retorque all the bolts on the cylinderhead again, on 40Nm, and yes it was necessary.
After we cleaned and assembled the carburettor block we did some maintenance on the engine what is needed after an engine rebuild. We also found a SAFETY ISSUE: Not secured rear brake cable, so we installed a security pin.
After we cleaned and assembled the carburettor block we did some maintenance on the engine what is needed after an engine rebuild. We also found a SAFETY ISSUE: Not secured rear brake cable, so we installed a security pin.
Notice the large amount of rust in this carburettor. Of course you will know that this will give problems.
Notice the large amount of rust in this carburettor. Of course you will know that this will give problems.
Notice the large amount of rust in this carburettor. Of course you will know that this will give problems.
NEVER USE THIS RUSTY FUEL TANK.
NEVER USE THIS RUSTY FUEL TANK.
DO NOT USE THIS RUSTY FUEL TANK. De-rust and seal the tank before you will use the fuel tank again.
DO NOT USE THIS RUSTY FUEL TANK. De-rust and seal the tank before you will use the fuel tank again.
VERY DIRTY CARBURETTORS! This means cleaning the carburettors. We disassembled the complete carburettor block and cleaned these carburettors thoroughly.
VERY DIRTY CARBURETTORS! This means cleaning the carburettors. We disassembled the complete carburettor block and cleaned these carburettors thoroughly.
VERY DIRTY CARBURETTORS! This means cleaning the carburettors.
VERY DIRTY CARBURETTORS! This means cleaning the carburettors.
VERY DIRTY CARBURETTORS! This means cleaning the carburettors. You should know these carburettor set has been rebuild just before the client got these carburettor set.
VERY DIRTY CARBURETTORS! This means cleaning the carburettors. You should know these carburettor set has been rebuild just before the client got these carburettor set.
We know when rust is in your fuel tank it will flow into the carburettors, the carburettors become very dirty of that rust. We also know that the float valves won't close anymore and the fuel with rust will seeping into the cilinders. So we removed the carburettors for inspection. Again a good job as you can see: VERY DIRTY CARBURETTORS!
We know when rust is in your fuel tank it will flow into the carburettors, the carburettors become very dirty of that rust. We also know that the float valves won't close anymore and the fuel with rust will seeping into the cilinders. So we removed the carburettors for inspection. Again a good job as you can see: VERY DIRTY CARBURETTORS!
We collected the petrol on the CENTER cilinder, we also spilled a lot of petrol when we removed the SRIS valve. In total we collected more than 200cc pertrol. As the petrol is very dark we did know that there was RUST in the fluid.
We collected the petrol on the CENTER cilinder, we also spilled a lot of petrol when we removed the SRIS valve. In total we collected more than 200cc pertrol. As the petrol is very dark we did know that there was RUST in the fluid.
On an UNKNOWN engine, even the engine has been rebuild by www.knalnaarpotz.nl we always DRAIN the engine first! As you can see we did a good job to do this. The LEFT and CENTER engine carters were filled to the top with petrol.
On an UNKNOWN engine, even the engine has been rebuild by www.knalnaarpotz.nl we always DRAIN the engine first! As you can see we did a good job to do this. The LEFT and CENTER engine carters were filled to the top with petrol.
This GT750-A did not drive a lot of kilometers. In total 19101km.
This GT750-A did not drive a lot of kilometers. In total 19101km.
Besides the maintenance jobs we will repair some problems, the client complained that after using the GT750 for 160km the engine won't run anymore.
Besides the maintenance jobs we will repair some problems, the client complained that after using the GT750 for 160km the engine won't run anymore.
Of course we will do some necessary maintenance what's needed after a engine rebuild, such as retorque the cylinderhead, checking ingition points, synchronizing the carburettors and tuning the carburettors. This because the client installed himself the engine and carburettors at home.
Of course we will do some necessary maintenance what's needed after a engine rebuild, such as retorque the cylinderhead, checking ingition points, synchronizing the carburettors and tuning the carburettors. This because the client installed himself the engine and carburettors at home.
Just for tagging: Motor revisie GT750 GT550 GT380 T20 T500 GT250 T350 krukas revisie cilinder boren en honen polijsten onderdelen waterpomp zuigers onderhoud reparatie vervanging wet-blasting
Just for tagging: Motor revisie GT750 GT550 GT380 T20 T500 GT250 T350 krukas revisie cilinder boren en honen polijsten onderdelen waterpomp zuigers onderhoud reparatie vervanging wet-blasting
START SITE 30082025: A client brought his beautiful GT750-A for some repairs to www.knalnaarpotz.nl. We did a complete engine rebuild before but the client complained that after 160km driving the bike won't run anymore.
START SITE 30082025: A client brought his beautiful GT750-A for some repairs to www.knalnaarpotz.nl. We did a complete engine rebuild before but the client complained that after 160km driving the bike won't run anymore.

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