1968 Suzuki T500 Cobra

Some pics of the teardown.
 

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At least the wheels are in good condition.

Got a close-up of the case damage and it looks like the battery box has a broken tab, too.
 

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Going to get the crankcase welded? There's 2 sets on ebay, one with a chunk missing in what looks to be the same spot as yours.

And this one. Pretty pricey but looks to be in good condition

http://www.ebay.com/itm/SUZUKI-T500-T-500-1968-68-COBRA-10736-ENGINE-CRANK-CASES-CASE-SET-UPPER-LOWER-/271124845970?hash=item3f204cd592:g:lvEAAMXQTghRSm3-&vxp=mtr
 
hey matt

if you cant get it welded there send it to me i will fix it for you and send it back
 
Powder is in process.
 

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Started the engine tear down.

Anyone have any tips for removing the head studs? I was able to get two of them off using the double nut method. Then my wrench broke.
 

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Just ordered a stud extractor from online, too. Thinking maybe an impact wrench might do the trick?
 
VonYinzer said:
Yeah... I know thay size stamping anywhere. No bueno.
Ha, my 12mm is stamped 14mm on the opposite side

Sent from my SM-G900V using Tapatalk
 
I finished up tearing down the engine last night.

Transmission looks pretty good to me, so I maybe got lucky on avoiding the dreaded fifth gear oiling issue? Speaking of which, I'm supposed to make some modification to increase the oil capacity. Anyone have the details?

Looks like the pistons are already .5mm over, so I'm not the first one to open her up.

I started clean up on the oil lines and oil pump, too.

I also took the opportunity to order a stud extractor and a impact wrench so I can pull the last of the head studs that broke my wrench.
 

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In the lower crankcase, there is a small dam sectioning off a corner of the case. This is where the oil check screw is. The dam is raised so that the oil must be filled to a higher level before spilling over into that section and then out the check screw.


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