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I read a thread elsewhere about addressing this matter w/o the ridiculous expense of OEM washers by substituting o-rings of, naturally, a specific size that will crush and seal when the bolts are tightened. I believe I will be taking this route.

I think the main reason is the accumulation of rust between the studs and their respective bores combine with the adhesion of the base gasket to form one hell of a bond. At least, that's my opinion.

Thought I'd update this thread with some good news. Not only was I able to free up the stuck pistons but I was extremely lucky to have been able to remove the block without the use of a puller. Yee haw!

Freed up the stuck pistons of my GT750 over the weekend. No easy task in itself. Then, I thought I'd push my luck and try to pull the cylinder block. Ha!  It took awhile and a lot of levering and shimming with strips of wood but I succeeded! Next up is to ship it out for Nicasil plating.

I was saddened to learn of Dale's passing. I was lucky to have met and talked with him a few yrs ago while touring WTT with an old riding buddy of mine. He made us feel right at home.
Ironically, a few yrs later, the same buddy was in line at a fast food place when he struck up a conversation with a motorcyclist in line in front of him. Somehow the topic of WTT came up. When my buddy told the guy in front of him how nice Dale was, a person behind my friend tapped him on his shoulder, explained that he had over heard his compliment and wanted to thank him for the kind words. It was Dale. Small world.
RIP Dale

Having watched several videos on You Tube, I was impressed and new to the procedure you described. Very tempting.
As for your question..... yes, that's the one I have to pull the block on. And, its been so long since I last messed with the jetting that I honestly don't know if I got it right or not. Sadly, my memory doesn't compare with yours. To say I'm impressed with yours is an understatement. :)

If you're referring to the Suzuki Two Strokes forum, I posted a similar request there on 1/31. 32 views as of this morning but no responses. :(  Looks like I'll be making my own in the not too distant future. IF I do, I'll definitely make it available to others that find themselves in my position.

Some of you may have seen my post in the Suzuki 2 Stroke forum. I thought I'd post the same request in here. I'm rebuilding the top end on my GT750 and will need a puller to remove the cylinder block. Before I make my own, I thought it'd be wise to see if anyone has one they'd be willing to loan me. If they do, I'll pay the shipping both ways and even give the loaner a deposit if desired. Please PM me or respond here if you have one you'd be willing to loan me or know of someone who does and will. Thanks.

Congratulations on all that you have accomplished and best of luck achieving your latest goals.
Incredible!!

My thoughts, exactly! ;)

I've wanted a CX650 to cafe for quite some time now. I agree with rodneya that they can be made to look extremely sweet. I'm sure they sound as good as they look too. Kind of poor man's Guzzi, in my opinion.

Someone got a helluva deal on that RD. As for the DS7, ironic that you should post that link as I'm in the process of getting an RD350 powered DS7 cafe back on the road.
I'd post a recent pic but the file is too large. Anyone know a link to a service that reduces file size? I think there'll be a few on here that might want to see what I'm working on.

VERY nice one. If it were reasonably closer to TN, I believe I'd be bidding to win.

Thanks for the quick response. I did a little searching after posting that and found that it is a 14 mm thread, as I'd thought. It was the pitch I was uncertain about. I now believe its a 1.5 mm pitch. Fwiw, I decided to try a metric thread file vs buying a die to clean the threads. Should be interesting.
Thanks again.

I need to chase the threads on the front axle of my '73 DS7. Does anyone know what the thread specs are so I can order a die?
THANKS!!!