First Glimpse Of The GT

Vincent · Banned Joined: 16 Oct 2006 Karma :

https://www.youtube.com/watch?v=lynL7IUGXLQ

Hopefully my barrels have been off relatively recently I won't have to go through this nonsense Shocked

https://www.youtube.com/watch?v=DLEhNZ9SQVM
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Vincent · Banned Joined: 16 Oct 2006 Karma :

Head now off.....pistons and bores look good....and on original bore, which is nice Cool

There's just one mark on the R/H pot that looks like a partial nip-up. The head gasket is being a real pain to get off, I'm not sure that this engine has ever been split before which is pretty amazing considering the age Shocked

Strangely...or maybe not....the head gasket was covering six of the water jacket holes. I know they don't all need to be clear for the coolant to circulate but it still seems a bit odd Confused

Check out the exit hole under the thermostat, on the pic of the head....completely blocked up with rusty crap! This stuff had built up where the water jacket holes were blocked by the head gasket.

https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/P1013236_zpsjhnmqzlh.jpg
https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/P1013230_zpszcrdxcaz.jpg
https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/P1013231_zpsispojutl.jpg
https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/P1013239_zpsfzc1gnkn.jpg
https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/P1010007_zps1hr9rnla.jpg
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Vincent · Banned Joined: 16 Oct 2006 Karma :

This is puzzling me., there's a popular rebuild video for this engine and the guy doing it says that, on this shaft, (circled in pic), the washer goes on top, and not underneath. On my spare bottom end, the one I intend to use, the washer is underneath. It's the oil pump drive so pretty crucial I'd have thought. I want to know if it's responsible for the main bearings letting go. Thinking

https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/Oil%20drive%20washer_zpsnosvx6er.jpg
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Vincent · Banned Joined: 16 Oct 2006 Karma :

This is a photo of someone elses motor showing the plate I may need to remove the cylinder block if it's badly rusted in place. It bolts onto the block as in the pic and then you line up other holes, weld nuts in place and use bolts to screw down onto the top of the cylinder bolts. I don't know how bad mine is, the stud that remains in the top of the block when you remove the head came out very easily which could be a good sign.

https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/GT750%20Block%20puller%202_zpswuv5yknw.jpg

https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/GT750%20block%20puller%201_zpswd7ytd9o.jpg

Thank **** there are people on the interweb putting this info out, I'd have been swinging my lump hammer around for hours Smile

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Vincent · Banned Joined: 16 Oct 2006 Karma :

These are the three screws that hold the thermostat cover on on. One snapped, the other two came out with Mole Grips. There's a bit of pipework on the other side of the head that I can see snapping the corner of the head off if I'm not careful.

https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/P1010019%202_zpswd5ftvxu.jpg
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N cee thirty · Banned Joined: 31 Jan 2010 Karma :

first time in a couple of years a thread worthwhile of watching

gives me the 2t itch again Very Happy

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'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

Vincent · Banned Joined: 16 Oct 2006 Karma :

It's my brothers service tmrw, I'm going to try and make use of the trip to Essex and if I get chance, will drop the old, original crank in for a rebuild.
Aiming to have the newer engine that's in the bike running this week.

EDIT; This was a good idea but would have worked a lot better if I'd have remembered to stick the crank in the car Rolling Eyes

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Vincent · Banned Joined: 16 Oct 2006 Karma :

Cleaned up the original cases a bit for the blaster yesterday and found these marks on the entry to the transfer ports. I havn't got a clue what caused them or if they will affect gas flow. The other two ports have similar marks but this is the biggest:-

https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/P1013235_zpschlenicv.jpg

Also found:-

https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/P1010001_zpswekn4klw.jpg

And:-

https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/P1013240_zpsfflhjyzx.jpg
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Vincent · Banned Joined: 16 Oct 2006 Karma :

Finally got the puller finished to get the cylinder block off:-

https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/P1013207_zpsabh7gxcg.jpg

Should be able to drop the cranks and cases off at the crank builder blokes place this weekend. I'm going to give him everything and ask him to put the bottom end together using whatever bits he thinks are best.
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Vincent · Banned Joined: 16 Oct 2006 Karma :

Cooking with gas now Cool

Cylinders off using my excellently made puller. OK so a couple of the M8 holes were out slightly, easily fixed by enlarging the holes 0.5mm Wink

TBH, I think the cylinder block would have come off without it, apparently, the area under the exhausts is really strong, and if you fasten a block of wood on there you can give it a good swing with a sledge hammer. The puller was probably more fun though....making your own tools is cool IMO. Incedentally, if any GT owners find this thread while desperately trying to find a way to get their seized cylinder block off, you're welcome to borrow the puller, just PM me Thumbs Up

grr666 · Super Spammer Joined: 16 Jun 2014 Karma :

Hats off Vincent. I wish I had mechanic skills beyond the very basics.
I'm destined to have to pay a mechanic to do anything complex like a rebuild. Shame because I love older
bikes, but I don't know how to fix one up, nor do I have anywhere to do so really at present. Sorry to hear about
your brother too. Get it going again to honour him and go on a cool trip somewhere on it. Thumbs Up

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RhynoCZ · Super Spammer Joined: 09 Mar 2012 Karma :

Vincent · Banned Joined: 16 Oct 2006 Karma :

Ready for out. Rumour is that the window cleaner's on his rounds tmrw, little does he know......... Twisted Evil

https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/P1013230_zpsyertemtb.jpg
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Vincent · Banned Joined: 16 Oct 2006 Karma :

Vincent · Banned Joined: 16 Oct 2006 Karma :

Engine 2....the later "B" model engine that was in the bike is now split. All is good, no damage, no broken bolts while pulling it apart etc. The crank looks and feels OK. I need to get it checked over but maybe it can go straight back? Would save me 500 knicker if so Cool

I think a lot of people take the attitude that if the cases are split you may as well change the seals...and while you've got the crank in pieces, you may as well replace the bearings........or, I could just change the outer seals and take a gamble on the centre one and the bearings. The engine has been split before cos there's RTV sealant everywhere, but the cylinders are on original bore so it can't of done a lot of miles Thinking

https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/P1013243_zpsqshyalw8.jpg

In case, (no pun is intended), anyone is interested, I may tag this pic showing the basics and what does what. It's fairly basic but has a couple of unique to Suzuki design thingys.

https://i77.photobucket.com/albums/j71/Drewskovitch/Jap%2070s%20bike%20toys/Bike%20toys/P1013235_zpsfmlsjubc.jpg
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Vincent · Banned Joined: 16 Oct 2006 Karma :

Just got a great bargain Cool

2 sets of pistons and rings, 1 x 0.5 over, 1 x 1.0 over
1 complete set of carb repair kits
1 front master repair kit

Total.........£158 Shocked

I've saved about £600 knicker there Cool

Now I can afford one of these:-

https://oldjapanesebikes.com/blog/2012/07/30/elz2coil-accent-electronic-ignition-system/
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Pete. · Super Spammer Joined: 22 Aug 2006 Karma :

If I were where you're at right now I would do the following:

This would give you maximum result for minimum spend and effort and the engine should look and run like new if the crank's good. I can point you at a guy who lives out somewhere near Framlingham who used to have a wet-blast cabinet if it helps.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good Very Happy

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

Very nice to see the GT750's most private area all open and exposed like that! Laughing

The one thing that struck me most from the pictures though is just how much wider is that crank shaft than it needed to be?

I may be going off on a silly tangent here, but what if they had moved the primary drive to the outside, and lost the huge generator for a neat little piggy back alternator, and made it with a compact cassette gearbox from the start?

If all the above was the reality I reckon the GT750 engine would have become a cult sought after two stroke special builders motor of choice long before the RG500 and RD500 engines were created.

It would have also been interesting to see those pistons at that mileage if it could have been run on modern fully synth race oil from day one, as I expect cheap and simple two smoke oil has caused a lot of the burnt carbon/oil deposits on them?

Vincent · Banned Joined: 16 Oct 2006 Karma :

Vincent · Banned Joined: 16 Oct 2006 Karma :

Something I can't decide......most Kettles have all the alloy poilished up, with just about all of the engine polishable, and the masses of chrome it's a lot of bling. If I'm going to keep the bike, do I really want to have to keep that alloy polished Thinking

I would have loved it a few years back but I'm not sure I can be arsed, (I'm 54 you know Shhh!

). I've seen a Kettle with the engine painted matt black and it looks pretty good Thinking

I don't want to be too tied down by keeping the bike original and I won't do anything that can't be easily put back to how it should be....but all that polishing, esp in winter Doh!

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Pete. · Super Spammer Joined: 22 Aug 2006 Karma :

Bores look like standard liners to me, not plated just bare iron. Put a magnet on them.

You need to sort the gasket faces, despite what you think. If you brought them to me I could demonstrate why.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good Very Happy

Vincent · Banned Joined: 16 Oct 2006 Karma :

Aye....I think I'm getting them mixed up with the 550 cylinders...some of them were plated...they look bloody shiny though Confused

I'm sure your right Embarassed

I'm not worried about the head surfaces, the head is pretty much scrap anyway due to the detonation.... but you could show me why I can/can't use the crank Wink

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Pete. · Super Spammer Joined: 22 Aug 2006 Karma :

Nothing wrong with that dome that can't be fixed in a few minutes. I made Iain's one as good as new from a much worse condition. He had bought a new head (which incidentally wasn't flat enough to hold compression and coolant) and you could barely tell them apart. He ended up using the one I fixed.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good Very Happy

Vincent · Banned Joined: 16 Oct 2006 Karma :

Was this using an insert? On a two stroke? I'm never too keen on altering heads...or having them skimmed, on two strokes that is. Whenever I'd seen it done, it would be done in the garden shed with a Black and Decker and usually ended in trears Very Happy

Like some of the extensive DIY porting jobs I've seen. I still need to try and find a head gasket that has the right size fire rings.
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Vincent · Banned Joined: 16 Oct 2006 Karma :

Got a result today...took the cases to a local soda blaster that had been recommended at it turns out to be owned by someone I grew up with. I was more of a friend of his brother who was my age but we all used to knock about together. I remember when he was really young he sucked his thumb and made "rasberry" noises with his other thumb which was stuck in his ear Shocked

His Dad was our primary school headmaster. He knew who I was even though I havn't seen him since the mid '70s and it turns out he's got some photos of me when I was about 10 Cool

Can't wait to see them next week...and the cases.

Also the Japanese seller that does really cheap piston kits on eBay has decided to post to the UK again so I don't have to get a mate in Oz to buy them and send them over Cool

By hook or crook I'm getting the crank measured this week so I know what I'm up against, no point in dropping it off at the rebuilders until I've got the cases so it's gonna be another 2 weeks at least. Back to Cambridge tmrw, 'think I'll take the clocks with me, strip them down and see if they can be tidied up. I think someones bodged the bezels a bit and once they're loose, they're a pain to get tight. If I can't get them looking good, they'll have to go to Canada to get restored.
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