Removing GT750 cylinder barrels

General discussion about Street two-stroke Suzuki motorcycles.

Moderators: oldjapanesebikes, H2RICK, diamondj, Suzsmokeyallan

User avatar
Suzukidave
Moto GP
Posts: 3980
Joined: Fri Oct 24, 2008 5:55 pm
Country: US
Suzuki 2-Strokes: GT750 x2 97 -1200 Bandit 86 GSXR1100
Location: Lancaster Pa.

Re: Removing GT750 cylinder barrels

Post by Suzukidave »

You can make up a puller plate that has L pieces mounted to both sides above the intakes and exhaust openings . Use the intake and exhaust openings to hold the plate down and use the pusher bolts as normal . First you need to pound the cylinder back down as if its cocked on the studs it will not come off .
the older i get the faster i was
dnaj11
On the street
Posts: 10
Joined: Thu Dec 03, 2015 6:55 pm
Country: usa
Suzuki 2-Strokes: re5 gt750

Re: Removing GT750 cylinder barrels

Post by dnaj11 »

That's an interesting thought. But I was also thinking about mounting a piece of angle iron on the exhaust and intake studs, using a hammer drill or air hammer against that to run. The cylinder either up or down. That bit adapter that Jeff used on his hammer drill looked really weird, not real sure what that was, but if I can find the adapter, it's worth a shot to try it.

Hey, I see you are in Lancaster. You're almost a neighbor. I live about 12 miles east of Hamburg, Pa, not far from Cabellas there.
User avatar
Suzukidave
Moto GP
Posts: 3980
Joined: Fri Oct 24, 2008 5:55 pm
Country: US
Suzuki 2-Strokes: GT750 x2 97 -1200 Bandit 86 GSXR1100
Location: Lancaster Pa.

Re: Removing GT750 cylinder barrels

Post by Suzukidave »

Yep .. just a bit south of ya .
the older i get the faster i was
dnaj11
On the street
Posts: 10
Joined: Thu Dec 03, 2015 6:55 pm
Country: usa
Suzuki 2-Strokes: re5 gt750

Re: Removing GT750 cylinder barrels

Post by dnaj11 »

Well the hammer drill did not work worth a darn. Couldn't even hammer the right side back to its original place, which I did the old fashioned way with a hammer and a 2x4. It's level again, so at least one side moves. Anyone have puller plate I can borrow. Guessing I can make the L brackets, or I will try more of the old fashioned way, turn the bike upside down/sideways and hammer with a board.
User avatar
jeff kushner
On the main road
Posts: 102
Joined: Mon Apr 21, 2014 6:09 am
Country: USA
Suzuki 2-Strokes: none
Location: North of Annapolis Md

Re: Removing GT750 cylinder barrels

Post by jeff kushner »

The adapter was a hilti bit adapter for the Black and Decker hammer drill. My GT750 was the ONLY time it didn't work but after breaking the block loose with the plate method, then having to continue to use the plate until the block was nearly all the way off, I understand now how tough they are to remove!!

If you don't mind a little drive, I have the plate/bolts/nuts that you could borrow to get it off. I'm near Annapolis and could meet you halfway to save you some driving.

PM me and let me know...and leave me your cell and I'll leave you mine.

jeff
Present: VStrom 1000 K7, Stock: '74 RD350,’75 GT550,'76 CB400F, '75 H2(purple), Modded: ‘75 GT550 restored & ported, '82 Yamaha 650Turbo running 18PSI,'74 H2B carbs-pipes-ported, project list:'72 & 2-'75 H1's, '82 Yamaha XV920, 74 GT750
smoketriples
On the main road
Posts: 115
Joined: Tue May 17, 2011 8:38 am
Country: UK
Suzuki 2-Strokes: GT750

Re: Removing GT750 cylinder barrels

Post by smoketriples »

Anyone selling a puller plate? I purely suck at drill and tap. I can take the instructions and pictures to a machine shop but I'd rather just buy one someone has used and doesn't need now. -Eric
Smoketriples
current stable:
'75 Zooki GT750 (rider)
GTandcbr
Yeah Man, the Interstate
Posts: 590
Joined: Tue Mar 10, 2015 12:35 pm
Country: WALES
Suzuki 2-Strokes: suzuki gt 550j
Location: Wales

Re: Removing GT750 cylinder barrels

Post by GTandcbr »

Scammer....DONT CLICK!
98 carb Blackbird and GT550j
User avatar
oldjapanesebikes
Moto GP
Posts: 3229
Joined: Sat Feb 07, 2009 12:43 am
Country: Canada
Suzuki 2-Strokes: GT750(Jx3,L,M,A,B),T500
Location: Ontario
Contact:

Re: Removing GT750 cylinder barrels

Post by oldjapanesebikes »

GTandcbr wrote:Scammer....DONT CLICK!
I've deleted the post - thanks for flagging it ! 8)
Ian

If at first you don't succeed, just get a bigger hammer !
RoyalViking
Still in the Driveway
Posts: 6
Joined: Sat May 13, 2017 5:19 pm
Country: USA
Suzuki 2-Strokes: GT380, GT750

Re: Removing GT750 cylinder barrels

Post by RoyalViking »

I'm about to disassemble my engine. I'm not sure if I need the plate. What is the best way to get the head off and then the barrel?
I'd rather be a racer for a moment than a spectator for a lifetime.
User avatar
Suzsmokeyallan
Moto GP
Posts: 4326
Joined: Fri Oct 24, 2008 9:11 am
Location: Mostly Barbados, sometimes Florida and western Canada
Contact:

Re: Removing GT750 cylinder barrels

Post by Suzsmokeyallan »

If the engine has never been apart or its left out in the weather you will most likely need a puller plate. Remove the head bolts first and look to see how dry and rusty down in the 11 stud holes are.
Two strokes, its just that simple.

69 Suz U70
69 Suz T500
72 Suz GT750 cafe
74 Suz TS250
74 Suz GTXVR project
75 Suz RE5
75 Suz GT750
76 Suz TS400
76 Suz GT750
81 Suz GSX1100
86 Suz RG500x2
88 Hon CR500
93 Hon CBR900RR
98 Suz GSF1200x3
15 Kaw Ninja H2
RoyalViking
Still in the Driveway
Posts: 6
Joined: Sat May 13, 2017 5:19 pm
Country: USA
Suzuki 2-Strokes: GT380, GT750

Re: Removing GT750 cylinder barrels

Post by RoyalViking »

The engine was assembled from a basket case in 2010. It is used in an A modified autocross chassis with a Comet CVT clutch. I ran it for one race and haven't run it since. It has been stored indoors since it was assembled.

Since it was apart when I bought it I have no idea how much effort it will take to get the head loose from the cylinder (I am thinking I can start with a puddy knife and break it lose). I want to be sure of how to go at it before I ruin the gasket surfaces.

Do I need to get a 2x4 and smack it with a hammer to get the barrels to loosen?

I've worked on air cooled 4 stroke engines and things usually came lose pretty easy.
I'd rather be a racer for a moment than a spectator for a lifetime.
User avatar
Suzukidave
Moto GP
Posts: 3980
Joined: Fri Oct 24, 2008 5:55 pm
Country: US
Suzuki 2-Strokes: GT750 x2 97 -1200 Bandit 86 GSXR1100
Location: Lancaster Pa.

Re: Removing GT750 cylinder barrels

Post by Suzukidave »

After seeing your comment that the engine was apart in 2010 it just may come apart a bit easier than we first feared . Your thought of the 2x4 and a bfh just may get the cylinder loose :up: . If you could post up a picture of what your setup is would be interesting .
the older i get the faster i was
RoyalViking
Still in the Driveway
Posts: 6
Joined: Sat May 13, 2017 5:19 pm
Country: USA
Suzuki 2-Strokes: GT380, GT750

Re: Removing GT750 cylinder barrels

Post by RoyalViking »

I was able to get the cylinders off the case. One stud had started to rust enough to hold things in place. I started with a puddy knife around the base gasket and worked side to side. The right side move easily once enough of the gasket seal was broken. The stud that resisted was nearest to the starter on the right. Then I stacked two puddy knives once I had a large enough gap. I just kept wedging whatever I had on hand until it raised enough to break free (along with a decent hammer and a 2x4).
I'd rather be a racer for a moment than a spectator for a lifetime.
alberaotey
On the street
Posts: 10
Joined: Fri Aug 18, 2017 3:55 am
Country: Hong Kong
Suzuki 2-Strokes: Kawasaki, Honda, Suzuki

Re: Removing GT750 cylinder barrels

Post by alberaotey »

Removing GT 750 Cylinder Barrels is easy and Suzuki bike makes it even more easier.
User avatar
Suzukidave
Moto GP
Posts: 3980
Joined: Fri Oct 24, 2008 5:55 pm
Country: US
Suzuki 2-Strokes: GT750 x2 97 -1200 Bandit 86 GSXR1100
Location: Lancaster Pa.

Re: Removing GT750 cylinder barrels

Post by Suzukidave »

alberaotey wrote:Removing GT 750 Cylinder Barrels is easy and Suzuki bike makes it even more easier.
There are a few on this list that may disagree with that comment :shock:
the older i get the faster i was
Post Reply