Suzuki GT185 1978 build

Mr Bernzo

Been Around the Block
Suzuki GT185 build
So this project started in mid 2013 sometime when I brought a bike I knew little about from ebay for about $80. I brought it for the disk brake front end, I planned to use it on another project bike. Soon I realised that that the other project wasn’t worth the time and effort and started to look at the rolling wreck that I had brought. Some googling later and I realised that it was a Suzuki GT185 2 banger and that it wasn’t really a common bike. It had no tank, seat, lights (unbroken or working) snapped handlebars, had been sitting outside for some time (read as years), rear guard bent out of shape, engine was seized and the bike could be classed a general basket case. Picture below with front end and exhausts off.
 

Attachments

  • DSC_0058.jpg
    DSC_0058.jpg
    497.3 KB · Views: 761
  • DSC_0059.jpg
    DSC_0059.jpg
    1 MB · Views: 614
  • DSC_0060.jpg
    DSC_0060.jpg
    1 MB · Views: 757
Re: Suzuki GT185 1978 buils

Oct 13 I started by pulling down the engine to see what it was like, if it was not salvageable, I would hit the abort button and sell the bike for parts. Left cylinder was seized by rust, once that was free, the engine came apart easily. Crank turned freely but left bearings had rust. Pulled the crank out and took it to an engineer for assessment. He told me he could rebuild it if I could find the bearings, seals and rods. Not available in Australia, so I ordered from the UK.
While waiting for parts and labour on the engine, I found a tank and tacho at netbikes.com.au in Brisbane, brought a seat and side covers of ebay, front wheel spacers & speedo drive from the USA, wheel bearings, steering stem bearings, speedo cable & brake pads online. Seals, master cylinder reco kit, points, condensers and other parts from Mick Hone Motorcycles (great knowledge of old Suzui’s). I decided to build the bike, ensure that the build was good & bike rode well before stripping, painting and making it shine. Got to work with all my new parts.
 

Attachments

  • DSC_0065.jpg
    DSC_0065.jpg
    1,014.1 KB · Views: 888
  • DSC_0070.jpg
    DSC_0070.jpg
    578.6 KB · Views: 568
  • DSC_0062.JPG
    DSC_0062.JPG
    989.4 KB · Views: 708
Re: Suzuki GT185 1978 buils

Jan 14 - I had fully rebuilt and balanced crank, new pistons and fresh bores. Assembly of the engine was pretty quick and easy. Took the Ignition switch to Lock Smith and got a key cut. Stripped, cleaned and re assembled carbs. Mounted engine, oil tank, connected wiring loom, connected a battery I had changed out of my dirt bike, mounted tank with a new fuel line.
By about March, it was starting to resemble a bike again. Tentatively turned the key, lights on the speedo and tacho came on, good start. Gently turned the engine over with the kick starter, then held my breath and thumbed the starter button for brief moment. Couldn’t believe it but it turned over! Time to get serious. Set the timing and points gap as per the manual, 2 stroke oil in the tank, a few litres of fuel oil mix in the tank (wasn’t sure if the oil pump would work) and new spark plugs. Held breath again, turned key, thumbed starter again for less than 2 seconds and she fired up! Ran rough, lots of smoke, but it ran.
So I ordered a carb re build kit, bought headlight, tail light and indicators from thirdgear.com.au and started on nutting out the mess that was once a wiring loom. With a 2nd hand switch block from the USA, and an old wiring diagram I soon had it nutted out. Mounted lights, some basic carb tuning and it was time for a test ride! A quick spin, some more tuning and it idled and ran. Still not real good but it ran, selected all gears and rode OK.
Middle of winter, low on cash and time, I discovered a crack in left hand cylinder that caused one side of the exhaust manifold to brake off. The project was put on hold for a while.
 

Attachments

  • DSC_0100.JPG
    DSC_0100.JPG
    748.3 KB · Views: 1,037
Re: Suzuki GT185 1978 buils

Nov 14, removed head, cylinder and got the manifold welded and machined. December, re assembled, started bike and test rode. What a difference. Much better power, smoother, faster and more fun! Jan 14, bike inspected by Classic and Custom Motor Cycle Club, on to Vic Roads for a Club Rego! Started looking for tyres. Pablo’s Tyres helped out a great deal, decided to go for a newer style tyre for grip and stability rather than a tyre just for looks, settled on Pirelli City Demons. Bolted on the number plate, slipped on the tyres, tubes and rim tapes then its first real ride. Whoohoo, what a blast. Still a long way to go but now I can legally and safely ride it!
The plan for now….
1. Suspension, down to the shop to find out what I can do to improve the fork damping.
2. Clubman bars
3. Probably replace shocks
4. Find a seat base and get a café racer seat upholstered. Current seat is too good to modify.
5. Shorten rear guard
6. Braided front brake line
7. Strip whole bike to frame, paint frame & swing arm black. Tank, front and rear guard’s, side covers as close to the original blue as possible.
8. Polish clutch cover, sprocket cover, fork legs
9. Replace damaged points cover.
Not sure what to do about wheel hubs, don’t want to strip whole wheel down right now. I have no experience building/truing wheels. Considering using an automotive alloy cleaner and see how that works. Any suggestions?
Down the track a little further…
• Rear sets
• Expansion chambers?
Any other suggestions?
 

Attachments

  • DSC_0170 - 2.jpg
    DSC_0170 - 2.jpg
    999.7 KB · Views: 550
  • DSC_0169.JPG
    DSC_0169.JPG
    1.1 MB · Views: 601
  • DSC_0167.JPG
    DSC_0167.JPG
    1,008 KB · Views: 819
  • DSC_0166.JPG
    DSC_0166.JPG
    1.1 MB · Views: 549
Re: Suzuki GT185 1978 buils

Nice smoker!i ve gone down nearly the same road with my almost finished rd....cant wait to ride her!
Do plan on painting it yourself?
 

Attachments

  • uploadfromtaptalk1426421453268.jpg
    uploadfromtaptalk1426421453268.jpg
    3 MB · Views: 545
  • uploadfromtaptalk1426421535365.jpg
    uploadfromtaptalk1426421535365.jpg
    2.5 MB · Views: 596
Re: Suzuki GT185 1978 buils

They were a great little machine...almost 40 years ago, I bought a smashed up one and fitted the engine, rear wheel and anything else that was shiny to a CZ 175. What a difference, that little half breed motorcycle ran like a champ.
I think you should try to leave it in stock condition, but I'm sure whatever way you go with it, you will have a blast! A good cleaner, elbow grease and aluminum paint might be a low cost way round on your hubs.
 
Re: Suzuki GT185 1978 buils

Ryan Stecken said:
Nice smoker!i ve gone down nearly the same road with my almost finished rd....cant wait to ride her!

Do plan on painting it yourself?

Nice RD! I would love an Rd or rz. Your engine polishing looks great. Plan on painting the tank, guards and side panels myself in the original blue colour an frame black. Going to try and polish my engine alloy and chrome myself to. Will be my first attempt at polishing.
 
Re: Suzuki GT185 1978 buils

goldy said:
They were a great little machine...almost 40 years ago, I bought a smashed up one and fitted the engine, rear wheel and anything else that was shiny to a CZ 175. What a difference, that little half breed motorcycle ran like a champ.
I think you should try to leave it in stock condition, but I'm sure whatever way you go with it, you will have a blast! A good cleaner, elbow grease and aluminum paint might be a low cost way round on your hubs.
I was planning to leave the bike completely stock but I just can't get the original parts I need for the right price or in good condition. So I am trying to build the bike without making any modifications that are not easily reversible.
Thanks for the tip on the wheel hubs.
 
Re: Suzuki GT185 1978 buils

Mr Bernzo said:
Nice RD! I would love an Rd or rz. Your engine polishing looks great. Plan on painting the tank, guards and side panels myself in the original blue colour an frame black. Going to try and polish my engine alloy and chrome myself to. Will be my first attempt at polishing.
Thanks :) i m going to paint my bike too,metallic blue.

Do you have experience on painting bikes or are you just as unexperienced as i am :) ?
 
Re: Suzuki GT185 1978 buils

I have some experience, I have not painted a frame before but I have done a few hugger and guards etc. Also done quite a few car repairs over the years. Definitely an amateur but I can usually get a good finish if I take my time.
 
New shocks arrived yesterday! YSS 300mm
The original suspension leaves a lot to be desired! Rear was hard and bouncy with bugger all sag.
Front is soft and bouncy. Seems to be no damping at either end.
I now have 5mm static sag at the back and 25mm dynamic with pre load set on its lowest setting.
oh, and the shocks feel like they have some damping!
Looking forward to a test ride. Then to see what i can do about the front end!
 

Attachments

  • DSC_0244.JPG
    DSC_0244.JPG
    1.3 MB · Views: 486
  • DSC_0241.JPG
    DSC_0241.JPG
    796.3 KB · Views: 478
  • DSC_0242.JPG
    DSC_0242.JPG
    1.1 MB · Views: 496
  • DSC_0245.JPG
    DSC_0245.JPG
    809.8 KB · Views: 472
Re: Suzuki GT185 1978 buils

New seat from Texavina just fitted.
f95479f3a60305ee04259774ee71c6e8.jpg
1561d3d99f5719d30a19e11de82d6b85.jpg
[/IMG]
Also some clubman bars and fork boots
a516761307a13c2a78e3d176a0e6de67.jpg
77bd07fcf633671d3e6acfecc325d76c.jpg
[/IMG]
 
Re: Suzuki GT185 1978 buils

So it's been a long time... and a child and change of career, but I finally got back in the garage. Brought a parts bike and stripped most of it down
9bb6541b475cbb9742882c0c985144e4.jpg


Sent from my Moto G Play using Tapatalk
 
Re: Suzuki GT185 1978 buils

Parts bike is really rough but the exhausts are what I wanted off it. Next was to work out how to fit the rear sets. Removed the original foot pegs and brake then made a template to mount the rear sets to. Need a shorter linkage for the gear change and to modify the brake rod.
795945b3646446e28d5155606384beef.jpg
95a40cbac4baf3dfc7ba11e2cfca03cf.jpg
193bfd63549d1ddb65728335d3c9953d.jpg
be1324e0cf76fc1ba65d17cdad499e36.jpg
530d38d9bfb43e52da27c64947074b90.jpg


Sent from my Moto G Play using Tapatalk
 
Re: Suzuki GT185 1978 buils

Mr Bernzo said:
Not sure what to do about wheel hubs, don’t want to strip whole wheel down right now. I have no experience building/truing wheels. Considering using an automotive alloy cleaner and see how that works. Any suggestions?

stripping the wheel down it's not that hard, and you're surely able to put it on again. I don't know about there, but here it costs 50 in the local currency to mount a wheel, and only 10 to just align it. So i went on google to see how to put it together, paying just to align and balance, with the rims, hubs and spokes on place. About polishing and cleaning the hubs, any metal cleaner, polisher will get the job done. Nice work until now, looking forward to see it finished! And nice seat too!
 
Re: Suzuki GT185 1978 buils

flamelspy said:
stripping the wheel down it's not that hard, and you're surely able to put it on again. I don't know about there, but here it costs 50 in the local currency to mount a wheel, and only 10 to just align it. So i went on google to see how to put it together, paying just to align and balance, with the rims, hubs and spokes on place. About polishing and cleaning the hubs, any metal cleaner, polisher will get the job done. Nice work until now, looking forward to see it finished! And nice seat too!
Thanks for the input. I brought the seat already finished with a re pro seat pan. It was expensive but worth it.


Sent from my Moto G Play using Tapatalk
 
Re: Suzuki GT185 1978 buils

The strip down has begun. Hopefully have the frame bare by the weekend so I can clean off 38 years of grease, 2 stroke oil and dirt. Then prep it to paint. Project bike on the stand, parts bike on the bench.
df7cf5aa162559706d863bf6595d6edf.jpg
d3780b4b1ef4f35bfee8143ddeca660c.jpg


Sent from my Moto G Play using Tapatalk
 
Re: Suzuki GT185 1978 buils

Frame is all stripped down, degreased and pressure washed
c8de832d7c097fdf5ca367ee5fbcdfb4.jpg


Sent from my Moto G Play using Tapatalk
 
Re: Suzuki GT185 1978 buils

Started work on the frame swing arm and centre stand. It's going to be a bit more work than I was expecting. There is more rust than I thought, nothing to serious though.
24d8749085eaf90674508154c858d3e3.jpg
0f70abfd7384f677d2005fbfdec0f068.jpg
0b7fcac92e86a3742ead9d2892fd8d63.jpg


Sent from my Moto G Play using Tapatalk
 
Back
Top Bottom