Removal of the cylinder

The cylinder is often stuck to the case and studs due to 30-40 years of rust. Using a thick steel plate with holes for attaching the cylider might solve the issue


Screw down the bolts down onto the studs who are connected to the case.




fasten the steel plate to the cylinder with screws



Gently screw the bolts one at a time, little by little until you have a “lift off” and the cylinder is loose.





Note: Remove the nut underneath the intake in the middle (right hand side of the tube). I didn’t and ruined the cylinder. Luckily I got hold of a new and better cylinder.

Lesson learned: Build yourself a man cave with better lighting and more space.

Cylinder nut

Welcome to my man cave

Man cave
A proud owner of a new Man Cave

Testing out a new type of blog. Trying to document my MC projects. Hopefully at help for myself an others with the same interest. Scroll down for for new posts.

The main idea with this blog is to use it as a reference guide for Suzuki GT 750  and GT 380.

Most of the posts are related to GT750 and new posts regarding GT380 will be added since the GT380J model is my latest projects.



Don’t hesitate to give me feedback and guidance if you see me doing it wrong.


A new MC garage

After a long time out in the engine overhaul I’m ready to continue. The priority canged to build my self a “man cave” I neede more space for my MC projects. The blogg will be updated with photos from the dismounting and assebly process of the GT750 engine.

The lathe and the milling machine are located in the room next to the MC garage. Quite handy when I need to make special parts and tools.

Engine removal

Engine removal :

A one man job if you do some preparation up front. Lift the engine and slide it easy out on the right hand side.

Engine on the table :

A chain block and some pieces of wood, the engine is ready for surgery. My back is still in a good shape due to some thinking before lifting. Much better to do the work indoors. Winter will soon come in Norway. Now I can spend quality time in a warm and cosy basement working on my GT

Preparing for engine removal

Today I have done the following

Disconnected wires from

1. Gear indicator

2. Timing points

3. Generator

4. Disconnected tubes from the radiator.

5. Disconnected tube from the 2-stroke oil reservoir

6. Mounted a frame of wood to support the engine.

7. Remove right footrest

8. Removed left side stand
9. Removed the brake pedal

Engine overhaul

Time for engine overhaul. Two years after I restored my A model I have to get new crankshaft sealings. Last time I had focus on the frame and paint work and didn’t know about the bad shape of the crank. The time frame doesn’t matter. I look upon this work as a therapy. I assume I will learn a lot of this project and it will keep me happy through a cold winter in Norway. Hopefully the kettle will be on the road next spring / summer.