Suzuki 2 Strokes

Just a question about service manuals for a GT550. I have a copy of the original GT550 Suzuki manual (1972-1977) supplied by e-ClassicBuke Manuals located here in NZ and while it has all the correct info and details, it lacks a lot of specific info and instructions on certain subjects such as the front fork strip down, service and assy instructions. This may have been the way Suzuki did this at the time?

There are other service manuals put out by Haynes, Clymer and Cycleserv which I can buy for the same GT550 range or combined GT380-550 range. Has anyone got any recommendation on which is the better more detailed service manual - thanks.

I've got both Haynes and Clymer, and while one is better than the other on some parts, the other is better elsewhere. So for reference, there isn't a lot in it - better to ask on forums where people actually do the sort of thing you want to strip/rebuild.

+1 to what Alan says. None is an infallible resource, but they've all got useful stuff in them.

The factory Suzi manual is good for having the definitive factory measurements and tolerances for checking components, and it's useful to have the Haynes and Clymer manuals because both have relatively detailed photos which show how things go together.

Then once you've read the manuals, come and ask here how it's REALLY done

how its really done...haha. for example in the manual for gt750 for removing cylinder block. gently tap cylinders with a rubber mallet. lift off. 12 hours later and 2 cans of pb blaster, 2 fabricated cylinder puller plates, sheared nuts, bolts, some welding, and about 1000 swear words later I got it off. "gently tapping with a rubber mallet just didnt seem to be enough".

No. The manual is correct. As long as you follow the directions exactly... in 1974.

ConnerVT wrote:No. The manual is correct. As long as you follow the directions exactly... in 1974.

The manuals aren't allowed to specify explosives! Something to do with homeland security...........

mikefealk wrote:
"gently tapping with a rubber mallet just didnt seem to be enough".

You need to gently tap with a 98 lb rubber mallet. "Gently" means carefully measuring the distance between a large tree limb 100 feet off the ground and the cylinder block and using the appropriately sized rope to suspend the 98 lb mallet between the tree and the cylinder, then you carry the mallet to the roof of your 3 story house and let it swing down onto the cylinder block. Do that 9 times and you should have the block loose enough to have the puller actually work.

Lol ya pretty much.

Syd wrote:Just a question about service manuals for a GT550. I have a copy of the original GT550 Suzuki manual (1972-1977) supplied by e-ClassicBuke Manuals located here in NZ and while it has all the correct info and details, it lacks a lot of specific info and instructions on certain subjects such as the front fork strip down, service and assy instructions. This may have been the way Suzuki did this at the time?

There are other service manuals put out by Haynes, Clymer and Cycleserv which I can buy for the same GT550 range or combined GT380-550 range. Has anyone got any recommendation on which is the better more detailed service manual - thanks.

None of the manuals are perfect. You also never know with these old bikes when some previous owner changed parts with parts from a different model bike in which case the manuals are useless anyway. I bought 4 sets of gauges for an H1A, and got the "wrong" gauges each time...only to find out I had an H2 front end on the bike.

Best way is to carefully disassemble and take pictures as you go so that you know how to reassemble. Use the specs for oil quantities, preloads, etc.

Jeff

The digital camera and a USB memory card reader Should be number one on parts needed list. What did we all do before the little marvels were invented? Seriously, do you need help with the forks?