Stuck Jug on a '74 T500

Need some help? Put your question up here. Many years of experience on the board to help you get up and running.

Moderators: oldjapanesebikes, H2RICK, diamondj, Suzsmokeyallan

Post Reply
User avatar
celt_rock
To the on ramp
Posts: 270
Joined: Tue Aug 07, 2012 10:31 pm
Country: USA
Suzuki 2-Strokes: T500, GT380, GS400
Location: Northern Vermont

Stuck Jug on a '74 T500

Post by celt_rock »

Hey folks,

Any ideas out there for a jug that just refuses to come off? I've got the head off, piston moves freely, all bolts are out but the bugger just won't budge. I removed the left head and jug without much difficulty, a little tap and it came free of the gasket. This one not so much.
Slow and steady may win the race, but without loud and fast it's just a waste
Craig380
Expert racer
Posts: 1254
Joined: Mon Dec 01, 2008 2:52 am
Location: Manchester, UK

Re: Stuck Jug on a '74 T500

Post by Craig380 »

It will be some corrosion between the steel studs and the alloy jug. Try running some Plus-Gas or similar releasing fluid down the stud holes, leave for 24 hours, then tap upwards with a rubber or nylon mallet on the exhaust port.

I don't know if it's available in the US but ACF-50 anti-corrosion fluid is great for things like this, it dissolves the rust.
1976 GT380 - wounded by me, and sold on
2006 SV650S - killed by a patch of diesel and a kerb in Feb 2019
2017 SV650 AL7 - naked and unashamed
User avatar
celt_rock
To the on ramp
Posts: 270
Joined: Tue Aug 07, 2012 10:31 pm
Country: USA
Suzuki 2-Strokes: T500, GT380, GS400
Location: Northern Vermont

Re: Stuck Jug on a '74 T500

Post by celt_rock »

Craig380 wrote:It will be some corrosion between the steel studs and the alloy jug. Try running some Plus-Gas or similar releasing fluid down the stud holes, leave for 24 hours, then tap upwards with a rubber or nylon mallet on the exhaust port.

I don't know if it's available in the US but ACF-50 anti-corrosion fluid is great for things like this, it dissolves the rust.
Thanks Craig, I just checked and looks like I can order it online for about $14. I've found the stud that is the culprit, I should have known, when I pulled out the bolt it was horribly rusted and when I put it to the wire wheel it unveiled a host of pockmarks and pitting, I can only imagine what the dowel looks like down inside. Before getting your post I filled the hole with Liquid Wrench. I'll let that sit and then give it a shot tonight. If nothing I'll order the ACF-50 (I imagine this won't be the only time I'll use it) and give that a go. Thanks!
Slow and steady may win the race, but without loud and fast it's just a waste
Pete O'Dell
On the main road
Posts: 185
Joined: Tue Oct 09, 2012 1:52 pm
Country: uk
Suzuki 2-Strokes: T500X2 GT500 GS750 GS500/4 KAWASAKI A1 GT250

Re: Stuck Jug on a '74 T500

Post by Pete O'Dell »

diesel fuel is one of the best penitrating fluids going, you can also make a pulling plate up using a head gasket as a template, bolt it on by the 8mm holes and put pressure on the studs with 10mm (or 12) bolts, use some heat helps if you have gas kit
Post Reply