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Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: Mr Bernzo on Mar 15, 2015, 06:30:57

Title: Suzuki GT185 1978 build
Post by: Mr Bernzo on Mar 15, 2015, 06:30:57
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.
Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Mar 15, 2015, 06:35:33
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.
Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Mar 15, 2015, 06:39:17
 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.
Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Mar 15, 2015, 06:49:06
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?
Title: Re: Suzuki GT185 1978 buils
Post by: Ryan Stecken on Mar 15, 2015, 09:13:31
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?
Title: Re: Suzuki GT185 1978 buils
Post by: goldy on Mar 15, 2015, 09:15:40
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.
Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Mar 15, 2015, 18:13:18
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.
Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Mar 15, 2015, 18:21:21
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.
Title: Re: Suzuki GT185 1978 buils
Post by: Ryan Stecken on Mar 15, 2015, 18:41:52
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 :-) ?


Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Mar 15, 2015, 18:48:39
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.
Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Mar 24, 2015, 20:31:12
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!
Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on May 02, 2015, 09:58:20
New seat from Texavina just fitted.(http://[IMG]http://images.tapatalk-cdn.com/15/05/02/f95479f3a60305ee04259774ee71c6e8.jpg)(http://images.tapatalk-cdn.com/15/05/02/1561d3d99f5719d30a19e11de82d6b85.jpg)[/IMG]
Also some clubman bars and fork boots (http://[IMG]http://images.tapatalk-cdn.com/15/05/02/a516761307a13c2a78e3d176a0e6de67.jpg)(http://images.tapatalk-cdn.com/15/05/02/77bd07fcf633671d3e6acfecc325d76c.jpg)[/IMG]
Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on May 02, 2015, 09:59:47
Just need the time to strip it bare now and paint it up.
Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on May 30, 2017, 09:28:22
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(https://uploads.tapatalk-cdn.com/20170530/9bb6541b475cbb9742882c0c985144e4.jpg)

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Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on May 30, 2017, 09:33:07
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.(https://uploads.tapatalk-cdn.com/20170530/795945b3646446e28d5155606384beef.jpg)(https://uploads.tapatalk-cdn.com/20170530/95a40cbac4baf3dfc7ba11e2cfca03cf.jpg)(https://uploads.tapatalk-cdn.com/20170530/193bfd63549d1ddb65728335d3c9953d.jpg)(https://uploads.tapatalk-cdn.com/20170530/be1324e0cf76fc1ba65d17cdad499e36.jpg)(https://uploads.tapatalk-cdn.com/20170530/530d38d9bfb43e52da27c64947074b90.jpg)

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Title: Re: Suzuki GT185 1978 buils
Post by: flamelspy on May 30, 2017, 11:18:54
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!
Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Jun 05, 2017, 09:11:27
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.


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Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Jun 05, 2017, 09:15:12
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.(https://uploads.tapatalk-cdn.com/20170605/df7cf5aa162559706d863bf6595d6edf.jpg)(https://uploads.tapatalk-cdn.com/20170605/d3780b4b1ef4f35bfee8143ddeca660c.jpg)

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Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Jun 12, 2017, 09:08:09
Frame is all stripped down, degreased and pressure washed(https://uploads.tapatalk-cdn.com/20170612/c8de832d7c097fdf5ca367ee5fbcdfb4.jpg)

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Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Jun 12, 2017, 09:10:54
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.(https://uploads.tapatalk-cdn.com/20170612/24d8749085eaf90674508154c858d3e3.jpg)(https://uploads.tapatalk-cdn.com/20170612/0f70abfd7384f677d2005fbfdec0f068.jpg)(https://uploads.tapatalk-cdn.com/20170612/0b7fcac92e86a3742ead9d2892fd8d63.jpg)

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Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Jun 12, 2017, 09:14:36
Also working on the rear wheel. Spokes are coming out easily, soaking the spokes and nipples in a rust remover working well so far. The top 2 spokes and nipples have been soaked, remaining have not. Also hitting the hub with a wire brush while the spokes are out.(https://uploads.tapatalk-cdn.com/20170612/265387b4e8d038e1f81fb80c285ee482.jpg)(https://uploads.tapatalk-cdn.com/20170612/010427c694eda7ee0a24ed6935d28316.jpg)

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Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Jul 03, 2017, 10:04:10
Got the frame preped and primed, and a fire in the shed to dry the primer. Bloody cold here right now.(https://uploads.tapatalk-cdn.com/20170703/926a75fb52ab4728c22fa27c5cf1de7e.jpg)

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Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Jul 03, 2017, 10:06:09
Frame, swing arm, centre stand, headstem and other parts all painted up.  (https://uploads.tapatalk-cdn.com/20170703/c250fd39bf9cb3c3f70a99783e485280.jpg)

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Title: Re: Suzuki GT185 1978 buils
Post by: flamelspy on Jul 03, 2017, 17:29:57
nice! keep movin!
Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Jul 04, 2017, 09:21:41
nice! keep movin!
I'm tryin'. I got some assembly done. Still a lot of cleaning, polishing and painting to go.(https://uploads.tapatalk-cdn.com/20170704/786ec603ce02c5561de431a697d647d1.jpg)(https://uploads.tapatalk-cdn.com/20170704/7dd05a38d678baf17df9deb5bd7a5c99.jpg)

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Title: Re: Suzuki GT185 1978 buils
Post by: flamelspy on Jul 04, 2017, 11:17:45
greater care, greater results. Many times a boring part, makes look like we're stuck in the project, but has direct influence in the final result.
Title: Re: Suzuki GT185 1978 buils
Post by: Mr Bernzo on Jul 11, 2017, 09:24:00
Slow but steady progress. Rear wheel finished and mounted. Some electricals on too.(https://uploads.tapatalk-cdn.com/20170711/b3eac9d417e0ed565b51fdacc7d00866.jpg)(https://uploads.tapatalk-cdn.com/20170711/9b4b9eb7039f793544b093587980ef23.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Jul 11, 2017, 09:28:02
This is my first time cleaning, polishing and trying to make an old set of forks look good. Quite happy with the progress I'm making. Not a mirror finish professional polish, but still a major improvement.(https://uploads.tapatalk-cdn.com/20170711/b6571efda8ee94f262c6eb42d9789688.jpg)

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Title: Re: Suzuki GT185 1978 buils
Post by: Maritime on Jul 11, 2017, 09:47:57
This is my first time cleaning, polishing and trying to make an old set of forks look good. Quite happy with the progress I'm making. Not a mirror finish professional polish, but still a major improvement.(https://uploads.tapatalk-cdn.com/20170711/b6571efda8ee94f262c6eb42d9789688.jpg)

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Nice job so far, if you stop about there it's easy to keep that level of polish without a lot of upkeep, if you go full mirror and actually take the bike outside and ride it, there is a lot more work to keep it shiny.  Looks good so far anyway.
Title: Re: Suzuki GT185 1978 buils
Post by: goldy on Jul 12, 2017, 06:34:55
Looking good, a little elbow grease every couple of months will keep them looking tidy, unless you keep it outside in the rain (which I doubt, after doing all this work)! Keep it going! :)
Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Jul 27, 2017, 08:37:10
Slowly bring this thing together. Have decided to completely strip down the front wheel and have a crack at rebuilding it. Should be interesting....(https://uploads.tapatalk-cdn.com/20170727/b7065079bdb467b0e6f689085c8c521c.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Jul 30, 2017, 08:53:53
Brought myself a cheap wheel truing stand on eBay, spent some quality time with you tube learning how to lace a wheel. Some trial and error but about an hour later and wheel laced!(https://uploads.tapatalk-cdn.com/20170730/bb0904a207794f095156708501f0945f.jpg)(https://uploads.tapatalk-cdn.com/20170730/40a1d4ea9ed8d7d00a1459ded635e7f1.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Jul 30, 2017, 08:55:54
Then you go to mount the wheel on the stand and realise that the bearings are too small for the stand. Doh. (https://uploads.tapatalk-cdn.com/20170730/9374cbf50622c91c146a79a2e2a401ed.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Jul 31, 2017, 09:29:28
Some creative thinking to get the front wheel true. Rear wheel fits on the stand.(https://uploads.tapatalk-cdn.com/20170731/bb2d44250613c1263b50a37d3d25c542.jpg)(https://uploads.tapatalk-cdn.com/20170731/12010ac85adfb144663d7be7a17c8e1c.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Aug 05, 2017, 03:13:00
Wheels on, starting to look like a bike. Now to paint and polish the engine(https://uploads.tapatalk-cdn.com/20170805/3e2e356ae3981b7a07b44c3b5c3d2759.jpg)(https://uploads.tapatalk-cdn.com/20170805/7efe73528d5ab2652d43384fc9f02e74.jpg)(https://uploads.tapatalk-cdn.com/20170805/ac6f7aea46268451980792e0e9c46a59.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Aug 12, 2017, 07:06:22
Spent some quality time with the polishing wheel. Clutch cover was really bad and had been painted. Ended up alright with a lot of sanding first. Managed to pick up a NOS points cover on eBay.(https://uploads.tapatalk-cdn.com/20170812/8e65c007e07a2bcd0253e8f7b1dc8be3.jpg)(https://uploads.tapatalk-cdn.com/20170812/6acefe3af05e7a2babe11716115636a4.jpg)(https://uploads.tapatalk-cdn.com/20170812/39d6d49404dcfcc8eb4eab8577a812a2.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Aug 12, 2017, 07:11:45
Painted the cases, cylinders and head then re assembled the engine. Very happy with how it came up. Still need to polish the sprocket cover and paint the oil pump cover.(https://uploads.tapatalk-cdn.com/20170812/d992094cb7932a97e05017f0ba7ddf0c.jpg)(https://uploads.tapatalk-cdn.com/20170812/490c4a5a179fc71d0529911f2417f101.jpg)(https://uploads.tapatalk-cdn.com/20170812/f9c1aef27b354a92813b888a887606a1.jpg)(https://uploads.tapatalk-cdn.com/20170812/9a17207485c84e1b4e0f97e913ccf4e9.jpg)(https://uploads.tapatalk-cdn.com/20170812/91eee7e6a8a5654106065e109342a55a.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Aug 12, 2017, 23:33:08
Physiological, a big step was made today. Time to crank this build up and get it finished for the distinguished gentleman's ride in September(https://uploads.tapatalk-cdn.com/20170813/1225ddd789ddbca7dabc2f13f2b9cf53.jpg)(https://uploads.tapatalk-cdn.com/20170813/f2b72abcbc5377208f09a42e4416176f.jpg)(https://uploads.tapatalk-cdn.com/20170813/c80262e22c6d8efd2b8e0984368dd69a.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Uglyrabbit on Aug 14, 2017, 10:18:22
Engine looks great


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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Aug 14, 2017, 16:27:50
Engine looks great


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Thanks, I used VHT hi temp paint and primer. I hope it sticks well.

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Aug 22, 2017, 09:02:52
Oil tank, chain and chain guard done. Working on the mud guards, side plates and fuel tank now. There's a lot of cleaning, sanding and priming going on.(https://uploads.tapatalk-cdn.com/20170822/fa17039ee3474270e1ad13d62b064e5f.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: stroker crazy on Aug 22, 2017, 09:12:14
Hope you make it for the DGR!

Crazy
Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Aug 22, 2017, 17:38:48
Hope you make it for the DGR!

Crazy
Thanks, so do I. I should be good to go. It's mainly just more paint and polish from here as well as some rear set mounts and linkages. Then maybe some late nights too.

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Aug 25, 2017, 17:45:45
Removing the original stickers off the tank. Shame, they were in good condition and looked good but the tank needs a re spray. Thinking about replacing them once painted.(https://uploads.tapatalk-cdn.com/20170825/cc44e45ab34f734992a3525419ca4581.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Aug 27, 2017, 06:57:02
Headlight, electrical and front indicators on today. Tank, guards and side covers are just about ready to paint.(https://uploads.tapatalk-cdn.com/20170827/a16740cf02856f77eb308d47ebd84a7d.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Aug 29, 2017, 10:04:23
Fuel tank and side plates prepped for painting. Time to make the 3 different colours of blue all the same. I cut down the rear mud guard by about a third, then sanded and primed. It was bent about 90 degrees the wrong way when I got the bike. Hopefully get the painting done this weekend. Then it's just exhausts and rear sets to go.(https://uploads.tapatalk-cdn.com/20170829/37b64f15aa396010d85daa9a1f46c08a.jpg)(https://uploads.tapatalk-cdn.com/20170829/d0a88f24bd89bf7c565faeba1e2a29db.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Sep 05, 2017, 09:24:20
Been bloody cold and wet here in Melbourne. Hard to find motivation to get out in the garage.
Ram Air air filter turned up from the UK today. I removed the original air box from the rubber manifold and replaced it with a pod. The set up on the left is the original. I couldn't find original or after market filter foam for the original air box(https://uploads.tapatalk-cdn.com/20170905/3d14cc5e67e9ea0d77bfe7e63fd108b4.jpg)(https://uploads.tapatalk-cdn.com/20170905/2bf876f6fdb042ec82d0d1da64af6971.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Sep 05, 2017, 09:28:23
Also made some progress with paint. I wanted to stay with the original colour but add a white centre stripe. First time doing and stripes. Turned out ok, not as good as I was hoping for though. First was a coat of white, then taped up the stripe, metallic blue then clear. Will need to add a couple more costs of clear I think.(https://uploads.tapatalk-cdn.com/20170905/a4b1465645a74984ad35d2399a0600d9.jpg)(https://uploads.tapatalk-cdn.com/20170905/3d5a3fa3e6738147912c760beabc0a3b.jpg)(https://uploads.tapatalk-cdn.com/20170905/a1e737bedabace0d9ee296cdc0b0d347.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Sep 05, 2017, 09:30:50
Starting to resemble a motorcycle again now. 3 weeks to go before the DGR ride. Time getting tight. Still need to make the exhaust and rear set mounts, then do the linkages for rear brakes and gears.(https://uploads.tapatalk-cdn.com/20170905/24a48352dc547b0e7d6ef30104fe9a2a.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: goldy on Sep 05, 2017, 09:33:55
Things are looking good...I like the colour and the engine ought to work pretty well with the new filter, especially where both carbs are still breathing through a common inlet. 
Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Sep 05, 2017, 09:35:48
Things are looking good...I like the colour and the engine ought to work pretty well with the new filter, especially where both carbs are still breathing through a common inlet.
Thanks. I definitely wanted to keep both carbs breathing together. The rubber manifold on this bike made it easy.


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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Sep 09, 2017, 03:31:29
Getting closer to complete.(https://uploads.tapatalk-cdn.com/20170909/7dca87a72ee32526fc3574834cbf67ac.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Sep 16, 2017, 09:00:29
Well it's done for now. All back together and running. Happy with the result. Still a few tweaks here and there to do. Had a good ride on it today.(https://uploads.tapatalk-cdn.com/20170916/089aaa4077a11961d8cc642e861e882f.jpg)(https://uploads.tapatalk-cdn.com/20170916/16c26580f8ceeb409a2d60bc8c4165f9.jpg)(https://uploads.tapatalk-cdn.com/20170916/709fee3bff130b18e65535e9154a0bee.jpg)(https://uploads.tapatalk-cdn.com/20170916/3938e34040b1e90f08097af6b295c55a.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: julian.allard66 on Sep 16, 2017, 13:25:27
Keep an eye on the float heights, for some reason they go out of adjustment, lean the mixture and hole the left piston.

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Title: Re: Suzuki GT185 1978 build
Post by: goldy on Sep 16, 2017, 15:14:29
Looking good! Ride-tune/ work out the bugs. Great results!
Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Sep 16, 2017, 17:50:22
Keep an eye on the float heights, for some reason they go out of adjustment, lean the mixture and hole the left piston.

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Thanks for the heads up, I will do.

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Sep 16, 2017, 17:52:46
Looking good! Ride-tune/ work out the bugs. Great results!
Thanks Goldy. I think I will get a trusted mechanic with 2 stroke experience to do a tune for me and ensure the fueling is correct.

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Sep 21, 2017, 06:27:14
Seems to be running lean. I have no baffles in the exhaust as they were cactus. New baffles coming tomorrow and size bigger main jets. Anyone have any experience jetting Suzuki twins?

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Title: Re: Suzuki GT185 1978 build
Post by: goldy on Sep 21, 2017, 06:36:15
Experience: tons. Advice: not much....except to say, be patient! You are going in the right direction, about the only other option is to find an original intake and filter.
Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Sep 21, 2017, 06:43:16
Experience: tons. Advice: not much....except to say, be patient! You are going in the right direction, about the only other option is to find an original intake and filter.
Haha, I have the original air box, the foam filters are stuffed though and I can't find any new ones. Don't seem to be available anywhere.

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Title: Re: Suzuki GT185 1978 build
Post by: goldy on Sep 21, 2017, 16:08:33
You could try making a filter...not as hard as you might think.
Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Sep 22, 2017, 05:12:14
New parts today. 2 new exahust baffles and  larger main jets. Tomorrow I delve into the mistery of carb tuning....(https://uploads.tapatalk-cdn.com/20170922/7e9fdebabfefa58630503a94cd03d0fa.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Sep 22, 2017, 22:23:59
Substantial improvement in performance.
I'm on the richest clip setting, half a turn richer on the air screw, and main jet from 72.5 to 75. More power all the way from take off to 100km/r. Will look at a larger primary jet next. Spark plugs are a little darker in colour but not looking too rich.

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Title: Re: Suzuki GT185 1978 build
Post by: goldy on Sep 23, 2017, 19:22:37
Sounds like you've got things going in the right direction. B.Z!
Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Sep 23, 2017, 20:41:47
Distinguished(https://uploads.tapatalk-cdn.com/20170923/4fe7188bd78f2e3d42332ae139ce8426.jpg)

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Title: Re: Suzuki GT185 1978 build
Post by: Odontologist on Dec 02, 2017, 08:10:53
Hey Mr Bernzo, Thanks for the build thread. I'm half way through a CX500 build but couln't pass up a bargain 1977 GT185 from Coffs Harbour in NSW (hence Bananas sign) for my next build. Yor GT looks great and is a credit to you. Although mine will remain under wraps for a while, I've drawn lots of inspiration from your build.
Cheers.


(http://www.dotheton.com/gallery/111030-021217060419.jpeg)
Title: Re: Suzuki GT185 1978 build
Post by: cxman on Dec 02, 2017, 12:58:53
can i send you mine now??
Title: Re: Suzuki GT185 1978 build
Post by: Odontologist on Dec 02, 2017, 16:30:42
Haha. Is it as much of a basket case as mine? Don't  think my wife will let me have 2 of these .

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Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Dec 02, 2017, 16:44:12
Hey Mr Bernzo, Thanks for the build thread. I'm half way through a CX500 build but couln't pass up a bargain 1977 GT185 from Coffs Harbour in NSW (hence Bananas sign) for my next build. Yor GT looks great and is a credit to you. Although mine will remain under wraps for a while, I've drawn lots of inspiration from your build.
Cheers.


(http://www.dotheton.com/gallery/111030-021217060419.jpeg)
Thanks, I have seen your CX500 build, your attention to detail is much better than mine. Feel free to hit me up with any questions. The GT engine should be a bit easier to rebuild being a 2 stroke. I have a 2nd one waiting in the wings for when I finish my DT250. Good purchase, you need to snap them up when you find them.

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Title: Re: Suzuki GT185 1978 build
Post by: cxman on Dec 02, 2017, 19:51:03
no mine is pretty good i have even found all the parts
cleaned a good set of carbs for it and put them back on

just have no time to get back to it
Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Jan 01, 2018, 07:11:43
The little GT is getting better every time I ride it. I brought a Jet kit from 6 Sigma and received an immediate performance upgrade through the whole rev range. Still tweaking the clip position and have 1 larger set of main jets to try. So far though, the richer I make it the better it runs.

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Title: Re: Suzuki GT185 1978 build
Post by: goldy on Jan 01, 2018, 08:06:40
You're still riding...I'm so damn jealous. I wish I lived in Oz, everything is a frozen wasteland up here. Anyhow glad the bike is treating you well and Happy New Year!
Title: Re: Suzuki GT185 1978 build
Post by: Odontologist on Jan 01, 2018, 18:33:59
Smack middle of summer downunder. In fact, mostly too hot to ride if you don the leathers and gloves.

Love this bike. ;D

How's the ride with the suspension upgrade....and what did you end up putting inside front forks?
Title: Re: Suzuki GT185 1978 build
Post by: Mr Bernzo on Jan 01, 2018, 18:59:15
You're still riding...I'm so damn jealous. I wish I lived in Oz, everything is a frozen wasteland up here. Anyhow glad the bike is treating you well and Happy New Year!
Sounds depressing! Good time of year to be riding here, can be hot though.

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