DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: Brodie on Nov 01, 2014, 05:29:11

Title: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 01, 2014, 05:29:11
Alright I thought I would start a build thread for the latest addition to my garage. I picked her up for cheap off a friend who knows I have been chasing a 2T thumper.
She has come straight from a farm and has only been sitting for about a year. As this is my first smoker I am up for a bit of a learning curve.
This bike will not be getting the same treatment the GS has been, this will be a quick and dirty Cafe build. Rattle can paint, sandblasting in the front yard and a "close enough" attitude.
The main thing I will focus on is having the motor running well. Cosmetics are not a big deal as this will be my new daily.

So the problems I was instantly faced with were two snapped bolts in the upper triple and one bar clamp missing. Lucky for me I was given a pair from my friend. I decided to focus on cleaning up the rear end first, then the front. After welding some nuts to the remaining thread the two bolts were easy to remove. But the throttle was a different story. I ended up having to drill the heads off the bolts as they were stripped out and there was no way any screwdriver would remove them.

Here are a few quick pictures with more tomorrow.
(http://tapatalk.imageshack.com/v2/14/11/01/f86be05775e68a0cac2255f2b0248028.jpg)
Title: Re: '76 Suzuki TS185, unnamed project.
Post by: Erskine on Nov 01, 2014, 09:18:52
Subscribed, small bike builds are the most interesting :)
Title: Re: '76 Suzuki TS185, unnamed project.
Post by: irk miller on Nov 01, 2014, 10:04:06
Awesome.  I'm start to search for a smoker too, and I don't know shit about them.  I'll learn along.
Title: Re: '76 Suzuki TS185, unnamed project.
Post by: Brodie on Nov 01, 2014, 11:50:16
Ok so from my narrow understanding this bikes lower end is lubed by the oil injection system.
So I need to have the bottle and pump.
Works a bit different to the outboards I am used to.
Title: Re: '76 Suzuki TS185, unnamed project.
Post by: WhyNot on Nov 01, 2014, 12:32:53
Subscribed, small bike builds are the most interesting :)


Me too...........wish I could get my little tinker toy off and running.

But, some of these builds I read don't make me feel to too bad, there's one I'm watching first post was in 2010.

So, my tinker toy build isn't to far off.

Interested in seeing where this one goes.
Title: Re: '76 Suzuki TS185, unnamed project.
Post by: Erskine on Nov 01, 2014, 12:56:26
Ok so from my narrow understanding this bikes lower end is lubed by the oil injection system.
So I need to have the bottle and pump.
Works a bit different to the outboards I am used to.

Yep Defo worth re-installing and not going pre-mix.
Title: Re: '76 Suzuki TS185, unnamed project.
Post by: Macbethpoe on Nov 01, 2014, 13:12:17
Yeah just get this thing rollin, looks like it would be lots of fun.  Be sure to get a ridiculous exhaust to really amplify that awesome 2-stroke sound! Haha and don't forget the GS!  ;)
Title: Re: '76 Suzuki TS185, unnamed project.
Post by: Brodie on Nov 01, 2014, 19:50:51
I am thinking about just flipping this pipe until I find something more suitable. I was planning to find a wrecked moped and use exhaust parts from that.
Title: Re: '76 Suzuki TS185, unnamed project.
Post by: Brodie on Nov 01, 2014, 22:39:10
I just removed the engine from the frame. It has quite a few spots where the previous owner has used... silicone.... to patch a few leaks and unwanteds such as the tach port.

I gave the engine a quick bath and she started to look a lot better. I also noticed I need a new rear brake cable.

So my plan is to leave the engine as it has good compression and focus on pulling everything down, replacing bearings, greasing spots and sandblasting the frame. After I get that sorted a quick carb rebuild and a few bits of dodgy wiring and we will be set.
Title: Re: '76 Suzuki TS185, unnamed project.
Post by: Brodie on Nov 03, 2014, 06:39:48
Did a bit of work on the wheels today. I pulled the rear off and sand blasted it ready for painting. I then attempted to remove the front axle, but the bike had other plans. So I removed the fork caps and got a bit of heat into the axle and spacers. After that came the hammer and all was right once again.
That propane torch has become my favourite tool.
After I blasted both front and rear rims I called up the tyre shop and ordered some shoes, this looks to be the first set of road tyres this bike has seen. As I am trying to keep this a very low budget build so I went with the cheapest tyres that will fit. So a Pirelli City Demon on the rear and a Bridgestone Bt45 on the front.
(http://tapatalk.imageshack.com/v2/14/11/03/03ca277625e1d9fb6fe6bbaa72e166b2.jpg)
(http://tapatalk.imageshack.com/v2/14/11/03/0083dccece1464f6815f36c6904ec6a4.jpg)
I can tell it has been jumped and had a hard life. There is a flat spot on the front rim, only small which should be easy to fix. The rear shocks are dead, the front seals leak and the retainer bolt at the fork base also leaks on both forks.
(http://tapatalk.imageshack.com/v2/14/11/03/712080986dbecbba42ca01509dc619b4.jpg)

Looks like a front end spruce up will be in order, along with new rear shocks. I have a set of Chinese shocks off an old quad I wrecked. They are about 2 inches longer that the set on there and have different sized bushes.
I was thinking of using those but now I am leaning towards having a set made when I have a pair made for my GS.

I also started sanding the tank. I knew it had a hole in it somewhere as one of the first things I noticed when I bought the bike was sticky fuel residue on the bottom of the tank. There is a small crack just below where the back of the tank sits on the rubber mount, nothing a bit of metal epoxy won't fix.
(http://tapatalk.imageshack.com/v2/14/11/03/ff278fba731d662b7f91fa2e53e552f1.jpg)
Title: Re: '76 Suzuki TS185, unnamed project.
Post by: stubanger on Nov 03, 2014, 07:16:08
Awesome little project! Got a couple ts sitting in my old van, this might just give me some motivation lol *subscribed*
Title: Re: '76 Suzuki TS185, unnamed project.
Post by: .Dave. on Nov 03, 2014, 12:31:30
Definitely following this build. Looks like it will be fun
Title: Re: '76 Suzuki TS185, unnamed project.
Post by: ABCanuck on Nov 03, 2014, 22:29:29
I was gonna offer you the new tach cable I was sent, but alas, shipping would be a bit. Still, yours if you want it.
Title: Re: '76 Suzuki TS185, unnamed project.
Post by: Brodie on Nov 04, 2014, 00:18:21
Hmm. I will see what condition my cable is in and let you know. Thanks mate.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 04, 2014, 05:19:36
Looks like I am up for new oil lines. I was considering it anyway and whist attempting to tape them so I could paint the motor one of them broke. I wonder where I can get a set made with clear hose. If I can't get clear I guess braided will have to do...

Ohh and AB, my tach is buggered. Must be why they removed the cable.

I decided on the name "Roker" for this bike. No real reason other than it is a Smoker, and the dutch word for Smoker is Roker.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 05, 2014, 06:23:37
Alright so it looks like the banjo bolts have a spring valve in them. Looks like I will be making my own lines.

I have a bit of pvc tubing at home but I am now sure how oil resistant it is. I will see if I have any of the right diameter and use that if I can.

The stock tube appears to get larger at the banjo joints. If I use a pipe of the same I.D. of that I would imagine there might be some flow issues with the pump, but seeing as there are check valves and it is only 1mm larger I don't imagine it to be too adverse.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 05, 2014, 19:17:14
A battlax on this mudslinger? Are you sure they have the proper size?

You're going to make your own oil lines. Also, you want them clear to be sure you have no air in the lines. Air can seep in at the joints so even if you're "sure" you can't be sure unless you can see it.

I found those check-valves on ebay. Not cheep, not easy to find. You may search elsewhere, as the valve is universal through Suzuki's lines. GT, T, TS, all the same valve.

If you're rebuilding your valves, you will need to completely disassemble them. Sonic bath etc won't do it. I'm sure the springs are buggered though so start searching.

Judging by the bodgey patch work...
(http://i.imgur.com/KQCVo.gif)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 05, 2014, 20:49:57
Front and rear wheels painted in epoxy gloss black. I didn't bother to file and of the burs off the rims. I want this too look like a trail turned cafe.
Just a little show but mainly about go.
(http://tapatalk.imageshack.com/v2/14/11/05/2610c30880e2c082bd819ba999486926.jpg)
(http://tapatalk.imageshack.com/v2/14/11/05/71bdb47d79bda8b9a73fe8aced7914a6.jpg)

I then got to work on the oil lines while the paint dried. (16hours or some bs)
I had some 5mm tubing laying around at home but I was concerned about the lack of pressure from the pump with the ID being bigger. So I went out and bought a metre of 4mm for a dollar.
Had to heat it to get it over the hose barbs but here we are. Old hose vs new and both new hoses.
(http://tapatalk.imageshack.com/v2/14/11/05/d860ea2135519279a8e64d5239f92584.jpg)
(http://tapatalk.imageshack.com/v2/14/11/05/c30d5fc64ac5de2ff327306c1cb663ba.jpg)

I have plenty of outboard 2t oil around. It is dark blue and should be very easy to see in those tubes. Just need to replace the feed line and bleed the system.

I was thinking about spraying wd40 down the line to clean the pump a little. It seems to have standard motor oil in it...

Ohh and I paint stripped the tank. Leopard rust spots everywhere.
(http://tapatalk.imageshack.com/v2/14/11/05/433afad02873b03cac4236f7195e9251.jpg)(http://tapatalk.imageshack.com/v2/14/11/05/0951975314163de2e20ccd8b5be6afbd.jpg)

The rims will go down to the tyre shop in the arvo and I will advise them of the wet paint. Hopefully I can pick them up Saturday, if not the Monday.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: irk miller on Nov 05, 2014, 21:00:13
The pattern of rusting on that tank is the strangest I've ever seen.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 05, 2014, 21:01:38
Suzuki... Probably some pot-steel
Title: Re: '76 Suzuki TS185 "Roker"
Post by: VonYinzer on Nov 05, 2014, 21:05:01
Pinholes in the paint. Likely from years of riding gravel roads.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: irk miller on Nov 05, 2014, 21:07:05
Your probably joking, but pot metal didn't use very much iron, if at all, because it raises the melting temperature too much. So no rusting of pot metal.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 05, 2014, 21:08:15
We are talking about "tin-foil chrome" Suzuki, right?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: irk miller on Nov 05, 2014, 21:11:50
Ha. 
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 05, 2014, 22:39:13
Pinholes in the paint. Likely from years of riding gravel roads.
Exactly what I was thinking. As there are none under the tank. Should be an easy fix, nothing a stainless brush, sanding and some rust converter won't fix.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 08, 2014, 20:30:28
Has anyone heard of Tygon fuel hose. I am thinking that this may be the go to replace the oil injection lines. The pvc I have used may hold up but I doubt it will last longer than a few months.

I did a bit of work on the frame yesterday getting it all pulled down to get ready for paint. I don't think the previous owner knew what grease was as all the bushing and bearings were total void of it. The neck still had independent ball bearings, the lower lot were replace with the wrong size balls as well. Hopefully I will be able to find some taper rollers of the same size.

When I pulled the swing arm off I noticed the left shock mount was... Loose. Looks like the welds broke, no doubt from repetitive jumping of the bike.
(http://tapatalk.imageshack.com/v2/14/11/08/a5adc676b57c260baddbe5e29d3a5954.jpg)

After a quick clean up I started to weld the mount back on. I tacked the outside to keep the mount in place while I welded the inside. I could not get a good photo because of the brightness off the cleaned steel but I will take a photo after paint to show the repair.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: irk miller on Nov 08, 2014, 20:41:34
Tygon is really good.  The F-4040-A is the fuel and oil tubing.  LP1000 is the fuel only.  The catch is the 4040 is yellow. 
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 08, 2014, 21:28:50
4040 is what I was looking at. As long as it is transparent I don't mind. It won't stay yellow with the oil running through it, and the pvc will go yellow anyway. Might be the go then. I am thinking 3mm for the oil lines and 6mm for the feed line. I still have to work it out but that seems the best, I have 4mm pvc on there at the moment and I am worried that the flow will be to weak from the pump.

I am starting to look at how to mount the seat, this will be my first cafe style mount. I am going to try and use the original mounts and lock point. My plan was to create a base plate for the seat to mount on and for the hinges to attach to. I will use spaces to give the seat an even height above the frame.

Anyway back to the garage!
Title: Re: '76 Suzuki TS185 "Roker"
Post by: ABCanuck on Nov 09, 2014, 00:13:37
Does yours have a 21 or 19 inch front.  Not that it matters, just curious.  All documentation I've found shows 19 inch but mine is a 21.  Wondering if it was a factory option.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 09, 2014, 01:12:50
Yeah mine is a 21. And didn't that stuff me up when I ordered the tyres only to call up a few hours later when I got home and had a look at the rim.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 09, 2014, 01:30:50
I just ordered some Avon Roadriders for the Black Bomber I'm finishing and the tyre arrived but it had a return label on it from a local shop. It also had a barcode that read "AM26 Roadrider" but it was actually a Roadrunner ???

Flushed the gearbox out? Checked for any leaks around the head? Have you checked the mounting flange and carby?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 09, 2014, 01:56:33


Flushed the gearbox out? Checked for any leaks around the head? Have you checked the mounting flange and carby?

I haven't even looked at that yet. All I have done to the engine is give it a quick clean and a bit of paint. After that I had a look at the oil lines.

If I have learnt anything from my GS it is deal with the engine last. So once I have a roller we can start looking at that stuff.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 09, 2014, 02:02:29
And buy a boat to forget about the bastard and move on! ;)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 09, 2014, 02:14:07
Hey I didn't buy that boat. And I didn't forget about the GS. I just don't have the funds to build it the way I want it to look. I am getting there. Slowly but getting there.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 09, 2014, 02:16:31
Hah just takin tha piss outta you cuz I like the build and wanna see more. I've been staring at that rim for weeks now wishing to at least see some rubber.

THE CL350 IS GOING FINE THANK YOU!
Title: Re: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 09, 2014, 03:46:51
Hah just takin tha piss outta you cuz I like the build and wanna see more. I've been staring at that rim for weeks now wishing to at least see some rubber.

THE CL350 IS GOING FINE THANK YOU!

There should be an update for the GS, I got tyres for it the other week.

So how is your CL350 going?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 10, 2014, 04:42:55
Wheels are back and the bearings will be replaced tomorrow. I had a bit of trouble getting the front bearings out but with a bit of heat they came loose.
(http://tapatalk.imageshack.com/v2/14/11/10/408dde47723114dc7b865cc62667ca18.jpg)
(http://tapatalk.imageshack.com/v2/14/11/10/58ac55f526aca86989b6525410d5ddc5.jpg)
I spent today working on getting the seat onto the frame. I had to make a sub pan to mount the Roc City Manx seat to. Had a bit of... Plywood... Left over from the boat floor so I used some of that. It worked out quite well, I just don't like the weight of it. It isn't much but on a 185 ever bit counts. So I will get the router out tomorrow and get rid of some of the wood before I seal it and paint it.

I ended up using the stock seat mounts so that I could still get to the oil tank to fill it. I forgot to get pictures but I will take some tomorrow.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: damiansd on Nov 10, 2014, 15:19:46
More photos please. Wanna see the this seat.

Sent from my GT-I9197 using Tapatalk

Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 12, 2014, 06:19:35
Back on my work block now, sorry Damo. I will get photos on Friday when I have a bit of time.

It doesn't look like I can take too much weight out of the seat but I am going to give it a go. I have been thinking about remaking the pan out of steel.

Anyway I have turned my focus towards the electrical system while I wait for a few parts to arrive.
The electrics are 6v, which will not work for what I have in mind, an all led system. So I need to convert to 12v. I have done a bit of research and have found conflicting information.

So what I want to know is. If I hook up a 12v rec/reg to the 3 charging coil wires and the output to either a battery or capacitor will it all work. I have no clue about Ac and Dc but from what I understand most led need Dc to run.

Doing that would also allow me to remove some of the wiring. Here is the closest diagram I have found to the harness I have.
(http://tapatalk.imageshack.com/v2/14/11/12/4aac4a8f4323594134d042c1a05603e9.jpg)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 12, 2014, 06:46:07
As I understand, you only need to change the r/r and battery. A 4ah battery should hold everything up, it works great in my CB350.

I don't think you'd have to do anything to the ignition system, since it's charging coil is independent and fully AC.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 12, 2014, 06:54:56
Yeah by the looks of it the ignition system won't be a problem. Well aside from the fact that I don't have a key.

From what I was reading you can use a 12v regulator and run 12v lights of ac. If I use a reg/rec (I ordered 1 for $10) will the single phase 6v system be able to keep up?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 12, 2014, 07:00:30
These smokers are easy to "hot wire". Problem is to shut it off, you have to reach down and disconnect the ignition coil from the charging coil. ;D I ran like this for some time on an old Yamaha.

A single wave current would need a single wave rectifier. That's the extent of my limited knowledge. PM Sonreir, duh.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 12, 2014, 07:10:30
Yeah I am hopeful that Matt will see this.

I am considering creating a new wiring harness, but that is taking away from my "finish it quick and ride the piss out of it" build tactic.
I might see if I can get a locksmith to cut a key, locking the fuel tank and steering would be nice.
Title: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 12, 2014, 07:13:11
Suzuki are good at one thing and that's providing for their customers. Just call the nearest outlet and give them the code on the lock and they'll provide a key.

As I'm told, they'll even provide a free service manual if it's available.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 12, 2014, 07:15:11
Haha I am still waiting on 4 copper washers for my GS forks. I think I ordered them 3 months back. Not to sure about the local Suzuki, I will give them a call but they didn't have a listing for my GS when I was in there.

Ohh and I did take a picture of half the seat pan. Here it is Damo.(http://tapatalk.imageshack.com/v2/14/11/12/0becb045522bec8962e0a6feb4e81687.jpg)

Also the latch I epoxied in to the seat.
(http://tapatalk.imageshack.com/v2/14/11/12/c5c80e05a8d1ad6aa850557d5e756502.jpg)

And trimming the frame to let the seat sit flush.
(http://tapatalk.imageshack.com/v2/14/11/12/37956fcb7e959c4241d97bc1354e2705.jpg)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: irk miller on Nov 12, 2014, 08:27:26
The advice I got from BradJ is to run your lights off of a separate 12v reg.  Apparently, this was not uncommon to do with old enduros.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: damiansd on Nov 12, 2014, 15:47:51
I agree with Deviant.  Your alternator is throwing out AC. It doesn't care if you have a 6 or 12v regulator/rectifier on the end. Are you planning 6v indicators and 12v lights?

Sent from my GT-I9197 using Tapatalk

Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 12, 2014, 19:27:31
I am planning on running 12v lighting system and a 6v ignition. So from what I understand if I use a 5 wire 12v reg/rec and run the 3 charging wires into it I should be sweet.

Thanks guys. Electrics aren't my strong point.

Now I just have to work out if I want to use a battery or not. If I give the battery a miss I will have a lot more room and a lot less weight.
I think a capacitor might be the go. That and a low slung chamber rather than a high one.
Should give me enough room under the seat to store a tool kit and a beer or two.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Erskine on Nov 12, 2014, 20:39:59
I know jackshit but I think if you can retro fit a later cdi stator plate and pick up ignition will be a piece of piss and 100% reliable. I know its possible to use a C50 cub unit for 4 stroke singles. There must be a chinese clone 2 stroke system that you can adapt for peanuts. after all, they all need to go bang a roughly the same point regardless of cc?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 13, 2014, 20:12:50
It has electronic ignition on it so I think I am right with that. As long as the unit is all good. As for the key issue, I was quited $100 to have a key cut. Not to keen on that. I might call up a few other places.

At the moment I am drawing a new wiring diagram while I wait for paint to dry. Thought I might give the triples a lick of paint. Although I forgot to take a before of the lower as I was busy beating the bearing race off it.
(http://tapatalk.imageshack.com/v2/14/11/13/74e7feaa7be3e2f17c1bd64e36263841.jpg)
(http://tapatalk.imageshack.com/v2/14/11/13/8c67e8ae7f2f2f7c6b7479403af9c335.jpg)
(http://tapatalk.imageshack.com/v2/14/11/13/b748cdc758769351fb2dd235a54e6745.jpg)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 13, 2014, 20:15:25
Was the race that bad?

These keys were made in limited combinations, so they should be available from Suzuki. On eBay they have auctions for 4-digit Honda keys. Pick any combo you want. Try to find a Suzuki lot.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 13, 2014, 20:16:43
Was the race that bad?

It was ball bearings... and had no dust seal....

Easy enough to go tapers with dust seals and be done with it.

Ohh and just to see I tried the GS key. It didn't work.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 13, 2014, 20:29:19
Also, does anyone have a spare TS200 motor laying around... Might be a nice upgrade in the future if I enjoy this bike.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 13, 2014, 21:45:20
I finished drawing up a new diagram for the 12v convert. Question is will it work?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 16, 2014, 23:49:44
Guess I will just rewire the bike and see how I go. I have been looking into using a capacitor instead of a battery. But that can be worked out a bit later on.

I cleaned up the fork legs and gave them a lick of paint. I am really digging this expoy paint. First time I have used it, I normally stick with acrylic.

(http://tapatalk.imageshack.com/v2/14/11/16/1d057a6d8218ba72728767e1ff082c90.jpg)

I also finished painting the frame the other day but never got around to posting a picture.

(http://tapatalk.imageshack.com/v2/14/11/16/979af2bb1af83643c0da28704fef1f48.jpg)

When I went to rebuild the swing arm one of the bushes decided to explode into crust. So it looks like I will have to get two made up at work. I will have to see who is on in the workshop this week.

Also the new rear brake pedal arrived today, wrecker special. I gave it some paint at the same time as the forks.
(http://tapatalk.imageshack.com/v2/14/11/16/e27ba04725d5f87b2708f0f816b0212f.jpg)
Title: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 16, 2014, 23:53:27
Classic Bakelite bushing eh? Haha

Might find somebody turning bronze bushings today.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 16, 2014, 23:56:18
Classic Bakelite bushing eh? Haha

Might find somebody turning bronze bushings today.

Yep, good old crap. The new bushing will more than likely end up being some kind of scrap food grade plastic. Quite a few bushings get turned up at work for all the pumps we have so I am sure there is plenty of stock to make two bushings from.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 17, 2014, 00:52:28
(http://tapatalk.imageshack.com/v2/14/11/16/27c9351207c16c3f55df5550214d082b.jpg)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 17, 2014, 00:55:11
Nice original take on leopard print.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 17, 2014, 00:56:44
Thanks. I still have no idea what colour to paint it. As you can see from the seat I was leaning towards red.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 17, 2014, 00:59:28
I like that dark pomegranate shade. Would be mad with the black motor. Sand and bog up the tank so you can primer before it flashes over!
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 17, 2014, 01:02:27
Ehh it is covered in chain oil. And the inside if full of 2t oil and kero. I still need to fix the leak and such first.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 17, 2014, 01:06:29
Ah I leave petrol and 2cycle oil in mine as well. Pomegranate. Reminds me of the off-color shades popular with drag cars.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 17, 2014, 01:11:15
The paint on the seat is etch primer with a few coats of "anodized" red over it. I have been thinking about painting the GS with a dark Mazda red, think that might be the go for this bike.
(http://www.ofroads.com/wp-content/uploads/2012/04/2012-mazda-demio-13c-v-smart-edition-02.jpg)

Something along the lines of that. My brothers fiancée drives a Mazda 2 that colour so I was thinking of getting the colour code and getting some 2K made up in a spray can.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 17, 2014, 01:12:27
Maaaaaaaaaaaaaad
Title: Re: '76 Suzuki TS185 "Roker"
Post by: lukeglasso on Nov 17, 2014, 05:09:26
Nice progress there Brod's. Did you see in Palmy a cafe has opened up called Espresso Moto! Workshop glass wall at the rear, looks pretty cool.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 17, 2014, 05:15:44
Thanks Luke, decent work with the fork polishing on your CB mate.

I didn't hear about that, I am out of the social loop, I don't even have a facebook.
Actually this forum is really my only online presence.

Might be worth a ride down to once I finish the TS. The SR is about to get a bit of a makeover before it leave my garage for its new home.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: lukeglasso on Nov 17, 2014, 05:30:55
Thanks man. You are way ahead of me but a meeting down there for a coffee could be a good idea in the future haha.

Ooooo nice, looking forward to seeing how the sr goes.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 17, 2014, 05:34:45
Sounds like a plan mate, once both bikes are done ha.

I think the SR is just going to get a fresh coat of paint and a few bits I planned to do but never ended up getting done. I will leave the design to my mate who is buying it, more than likely I will be involved in the work though.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 17, 2014, 07:51:18
Well I just went searching for a key number so that I could order a replacement key.

First thing I checked was the ignition... yep someone pulled the cover off which had the number on it...
Ok lets look at the fuel tank, nope no number there either, but hey my screwdriver can lock it so that is cool.
Ahh the steering lock, success! Lets just hope it is the same as the ignition!

Until then I have rats nest of a harness that once belonged to a GS, I think there is an ignition barrel in there granted the wires aren't burned to a crisp.

If it works out that the key is different to the ignition... at least I can lock the steering.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 17, 2014, 08:09:46
Use a toggle for ignition, steering lock for security. Just like dad had done for his truck
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 18, 2014, 00:19:43
Oil lines V2. Some tygon line to prevent it melting or cracking.
(http://tapatalk.imageshack.com/v2/14/11/17/72ce1a8186ce7bff76927e9725a1bf22.jpg)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 18, 2014, 00:24:16
How'd you deal with the valves?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 18, 2014, 00:27:40
How'd you deal with the valves?

Well, thank you.




Honestly I have not looked at them just yet. They appear to be in the brass banjos. I am not sure putting compressed air through them is the best option. I was thinking of soaking them in kero and just pushing the springs in every now and then to loosen them up if they are stuck. But I am open to suggestions.
Title: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 18, 2014, 00:29:48
NO COMPRESSED AIR! Disassemble and clean the shit out of em!!! Replace springs if brittle or binding. Replace ball if any pitting.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 18, 2014, 00:35:05
NO COMPRESSED AIR! Disassemble and clean the shit out of em!!! Replace springs if brittle or binding. Replace ball is any pitting.

Haha I know, I know.

Yeah I have to have a look and see if they come apart. By the looks of them they don't. The bearing shop I go to has plenty of springs and I should be able to find some to suit.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 18, 2014, 20:58:54
After doing a bit of research it looks that my pipe may be a severely molested Bassani. It is quite messed up, needs a bit of work to get back to what it once was.
(http://tapatalk.imageshack.com/v2/14/11/18/ab4db17a7fa535035896e2c3e49725ca.jpg)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 18, 2014, 22:00:38
Ohh and Red, the check valves are fine. I just bled the system and all is well. This bike was never out of action for long.
(http://tapatalk.imageshack.com/v2/14/11/18/79e1d60b5ce9fbea28232f90841631f6.jpg)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 21, 2014, 19:00:46
Few more bits and pieces arriving. New neck bearings, fork seals and an oil cap.
(http://tapatalk.imageshack.com/v2/14/11/21/0c9365d0bf21364c080f1db717b2dac1.jpg)

Now I am just waiting on swing arm bushings and a rec/reg. Ohh and I am yet to purchase new running gear. I am thinking of going up a tooth on the front to get a little more top end out of her. Either that or 1 down on the back. I am not sure yet.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 21, 2014, 23:14:17
Just replaced my fork seals, only to find a chip missing out of one of the fork legs. It is above the seal so it should be all good.
(http://tapatalk.imageshack.com/v2/14/11/21/3acbbde7828a1e6358999a6075b5aa15.jpg)

From what I can find on the net the 1976 TS has a new fork setup from the older models. After looking for a while I have found it needs 122cc of oil. So after I get the forks back together I will use some of the 10w castrol that I have at home.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Erskine on Nov 22, 2014, 16:22:08
Jeez, cracking on at a fair old lick.
I've found this chart v. useful in the past:
http://www.wemoto.com/info/sprocket_gear_ratios/
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Nov 22, 2014, 16:26:08
Gearing Commander. But you knew that.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 23, 2014, 23:26:33
So my Reg/Rec arrived today, and wouldn't you know it they sent a 4 wire instead of a 5. So I can send it back even thought it was only $11, I can use it and just run one less pickup from the coils or I can buy a 5 wire and keep this as a spare.

Decisions Decisions.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 24, 2014, 09:06:04
Ended up wiring in the reg/rec, left the green wire free. I am only going to run LEDs and a capacitor so I don't need a massive output.

I am also thinking I am a bit sick of rebuilding carbs after having a velocity stack on my SR, and I am thinking Christmas is coming. Sooooo I am out to find an oko or koso flat slide carb that will fit (and the funds for one)

As for the exhaust I would prefer a low system but I will leave that until I have the bike together.

I am thinking of cutting, moving and skewing the pipe until it fits where I want it. No re design and hopefully the same length as it had.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 24, 2014, 09:10:55
Jeez, cracking on at a fair old lick.
I've found this chart v. useful in the past:
http://www.wemoto.com/info/sprocket_gear_ratios/

I try, it is all thanks to my new job and the partial sale of my SR. Easy to build a bike when you have funds and a four day week end every week.

Gearing Commander. But you knew that.

I am thinking one down on the rear might be the go. This will not be a highway bike. Max it will do is 70mph (I hope) as it will be my run to work and around town bike.

I still want to have the go at the lights and I feel one up on the front may subtract from that on the 185.

Just have to decide what I am willing to deal with. As long as it can outrun my SR250 I will be a happy man.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 29, 2014, 05:48:45
Ohh man I want these bloody swing arm bushings to show up.

In other news I have pre-approval from the bank to buy a Shed, but they said I had to have a house on the same block.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: damiansd on Nov 29, 2014, 06:06:59
Fun times ahead Brodie. Building or buying?

Sent from my GT-I9197 using Tapatalk

Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 29, 2014, 06:10:06
Buying, after talking to the missus for a while and asking her what she wanted from a home we finally decided that the house was not to big of a deal, as long as it is nice, has no carpet and has aircon then all is well.

But.... I want a shed, nay NEED a shed and she wants a yard. So we are looking at an 800m2 block with a shed and a small weatherboard house that has been renovated. I am going to have a look at it on Monday arvo before work. If I like it then I will put an offer in and go from there.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: damiansd on Nov 29, 2014, 06:16:26
Very cool mate

Sent from my GT-I9197 using Tapatalk

Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 29, 2014, 06:18:17
Yep, just means I will have to get my Deckson running for the step son to ride around on haha, it backs on to a park so I will just stick a gate in the back fence.

If we buy it lol.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Sheepinwolfs on Dec 07, 2014, 03:53:28
Mate, nice work so far. Are you keeping the frame silver? I like it. Making me look like I'm running at snails pace (which I definitely am).  Will be keeping posted.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 08, 2014, 14:49:07
After pulling the VM 26 carb down and giving it a good clean out I have decided that it is in a bit worse for wear state. It has quite a few scratches on the slide and there was an unknown insect that had made a mud home in the air circuit.

Ohh and I have a lead on another bike. Described as "a 100cc twin 2 stroke" I showed the bloke a few pictures and it looks as if it may be a Yamaha YL1 missing the chrome tank covers.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 08, 2014, 22:53:48
Well, the other bike is a LS2, not the twinjet I wanted but still, whos doesn't want a 2 stroke twin with just enough power to pull skin off a pudding.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 08, 2014, 23:04:53
And I thought my 50cc polini/blata was fast, but TWO of those big hard hitting barrels? Inconceivable.

Now THIS is podracing!
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Erskine on Dec 09, 2014, 19:13:49
Bring it on! Photos?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 09, 2014, 22:28:36
Ha not yet, bloke who I am getting it from is on his days off. Should have aome by Sunday.

As much as I will be hated by some, I do plan to modify it. 100cc and 10hp just isn't enough to hall my arse around. I have found a way to make it 155cc but all this is for a later build.

As for Roker.... THE SWING ARM BUSHINGS ARRIVED! So tomorrow I will start on putting her all back together for a quick run up the street.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 10, 2014, 23:11:58
New bushings are in. Swingarm is on and it is to friken humid to do anything else.

(http://tapatalk.imageshack.com/v2/14/12/10/7e6042dd19c79dc08d6ac8702eb5fc7e.jpg)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 05:57:07
Ohh and I forgot to mention I fixed the crack in the fuel tank. Used "liquid metal" it has held up on another fuel tank for the past 8 years so I trust it on this.
Just made sure to rough up the surface before hand to give it something to stick to.
(http://tapatalk.imageshack.com/v2/14/12/11/377c6d5fcc587c2a2778e76a0cf000b2.jpg)
(http://tapatalk.imageshack.com/v2/14/12/11/a216675f82a315e0001f9f5cda3e195b.jpg)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 11, 2014, 05:59:09
What brand makes it?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 06:41:37
Oh I am buggered if I remember. The brand name wasn't even liquid metal, the last lot was. It is a two part epoxy designed to bond to aluminium and steel.

I will have a look at the tubes once I am home tomorrow. I used the same stuff to patch a hole in my boat and it is still going strong.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 19:27:23
It is called Loctite 3805.  Now get you some for that Superhawk!
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 11, 2014, 19:29:41
You used the same for the case and the tank?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 19:33:12
Not on the case yet. But I will. That stuff is magic.

So far I have used it on 2 tanks and 1 boat.

The TS has a few cracks in the stator cover so I will patch them with the 3805 and not have a worry. Not like there is any oil to leak out...
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 11, 2014, 19:37:06
Thanks! Anything that can stand up to petrol is magic.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 19:38:51
Yep! I used that shiz on my first bikes old tank. Held up for many years. I bent the arse end jumping it though. But hey, I was a kid, I had a motorcycle. What the hell did I know about not jumping hard tails. Nothing we couldn't straighten back out with a vice and a hammer. That is what I love about Hondas, I can hit them with a hammer and not feel bad. HA
Title: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 11, 2014, 19:48:33
Paaaaaahahahahahahahaha. Bahahahaha. Well I've seen old images of airborne Indian bikes, they were not kids and wore pomade helmets.

I won't be using this on a tank but good to know it can keep the PC afloat when I head to NZ for holiday :)

It takes a REAL rider to handle these jet skis on these roads 8)

There was a hard-tail Honda? Sounds beneath them.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 19:52:34
I would go for expanding builders foam to keep the PC afloat. Did you buy those sand tyres yet?
EDIT: TWO PCS! ARE YOU MAD?! I suppose the jetski restoration on one is bound to happen now!


Anyway here she is in all her restored glory! My first bike!
I put a hell of a lot of KMs on that baby. Needs a top end rebuild and some new points. Ohh and for some reason unknown to me the rear wheel raises up a little every revolution. I bought a new hub and new rim and it still does it. Ohh well, it is more a living room piece now. Once I have a decent sized shed it will be behind the bar!
Title: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 11, 2014, 19:55:21
OH, I thought you meant a motorcycle. She's a treat.

I'm trying to get my hands on a CT90 here listed for $100. Profit. The mini trails and trails sell for thousands fully restored here!
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 19:57:53
Yep same here. I am never letting go of that baby though. 1969 Model. I had to trade my trampoline to get it.
Title: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 11, 2014, 20:17:12
I can understand that, but the CT I'm after is just lunch money. I try not to get attached. The SL was a gift I promised Texasstar I wouldn't sell. The red frame is family's. You should see what DT, XT, RD and GT's are going for right now!

The grey Honda Hurricane is not mine. Client's. Just had to get a family photo since they are both very closely related. Even fooled you ;D

Count the Honda's, then add four that are scheduled this week, including an '81 Z50r like that monkey bike of yours ;)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 21:46:41
An 81 Z50R, what like this one?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 11, 2014, 21:48:36
The same, except it wasn't mining in Coober Pedy. XD
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 21:51:21
Ha that isn't under the house anymore, it is up with the other 3 minis. I jammed a worn out 125 into it and run a bit of oil in the fuel. Goes like a shower of shit, great when you are pissed and decided to go for a bash around the paddock.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 11, 2014, 22:18:26
"We choose to do this and the other things, not because they are easy, but because the sheep play hard to get."

I can't remember who said this, he resigned as GG of Australia soon after though ;D
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 22:19:55
Sounds like something a Kiwi would say.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 11, 2014, 22:21:56
Hey, I don't make the scandals, I just report em. :)

Has this thread fallen to shit or what? Carry on.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 22:25:21
Yeah you tend to do that to threads you arse.
This will get it back on topic.
(http://tapatalk.imageshack.com/v2/14/12/11/18d18c79431ac7f0e95e226e94f0ad7b.jpg)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: irk miller on Dec 11, 2014, 22:29:13
Woah.  I think I passed out.  What did I miss?  Silver frame, gold shocks, black rims- nice look.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 11, 2014, 22:40:06
Yeah.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 22:40:31
Woah.  I think I passed out.  What did I miss?  Silver frame, gold shocks, black rims- nice look.

You missed a heap of verbal diarrhea, well the internet kind.

Not much has happened. I found out that I don't need the key to start it, which is a good thing and a bad thing I guess.
I am not sure if the shocks will stay gold, or even if I will use those shocks, they were front shocks off a chinese quad I rode off a cliff into a river.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 22:41:34
Hey Red, you should start a shiz spewing thread so we can get this one back on topic. If it goes off topic to long it might just get deleted!
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 11, 2014, 22:42:40
You sure the key isn't bypassed? It's easy to cross the wires from the magneto and coil.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 22:46:59
Ehh I didn't have the barrel plugged in and it still had spark. The harness looks all stock. Well apart from my 12v adaptation.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: ABCanuck on Dec 11, 2014, 23:02:46
I'm not 100 percent sure but I think mine is the same.  Is it possible the key is lights only?  That seems pointless I know and highly unlikely.  Just wondering out loud.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 11, 2014, 23:07:01
I've bought a few scramblers that had just a killswitch, to eliminate battery. If your bike has no killswitch I would guess it's just a crossed wire. The wire from the mag could to straight to the coil or to the key. Cross em and you'll know when you try to kill it.

Just trace your wires :P
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 23:13:47
I put up a diagram a few pages back. It has a kill switch that ground the coil as well.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 11, 2014, 23:38:02
(http://tapatalk.imageshack.com/v2/14/12/11/64d78d241233fe10f8ed43e5889af4b6.jpg)
(http://tapatalk.imageshack.com/v2/14/12/11/cda3837ed2c3af1d23900289a2eebdc3.jpg)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 12, 2014, 00:00:56
Damn I need some proper bars for this thing. I was going to use a set of aluminium low rise but I don't think the kill switch will work if I go that route.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 12, 2014, 00:08:11
Why no?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 12, 2014, 00:16:06
Kill switch grounds to the bars. I suppose I could just run a ground wire...
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 12, 2014, 00:24:38
Isn't aluminium highly conductive? I mean it seems to ground the spark plugs well enough. What am I missing?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 12, 2014, 03:09:38
And here I though it was terrible.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 12, 2014, 03:22:33
I don't know the quality of these clip ons, but I know they aren't metal.

Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 13, 2014, 01:42:11
ITS ALIVE!!!  MUAHAHAHA!!

Anyway she runs. Put an old fuel tank on so I didn't mess up the TS tank while it is in paint. Cleaned the carb and pulled on the choke. 1 kick later and she came to life. Needless to say I was impressed! 1 kick!

Also, there are no bugs within a 1km radius of my house now either.

So left on the to do list:
1. Finish Paint
2. Cables
3. Sprocket/chain
4. Brakes
5. Seat pad
6. Exhaust.
7. Ride the blip out of it
8. Lights
9. Registration
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 13, 2014, 01:43:16
Did the kill button work? You running premix with the pump as well?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 13, 2014, 01:45:21
No idea and yup.

All I did was rig up the harness to make the coil fire and blocked the intake to kill the engine.

Still have to sort out the rest of the harness but it's mostly done.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 18, 2014, 21:43:48
Got the throttle cable sorted today, but wouldn't you believe it I have misplaced the small attachment for the end of the oil pump cable. If I can't find it I will have to make a replacement.

Other than that things are moving along quickly, nothing that really needs photos taken, bolts are going back in, wires on and such.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 20, 2014, 07:55:48
(http://tapatalk.imageshack.com/v2/14/12/20/75328cc26ade17bba89d318f59d18145.jpg)
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Redliner on Dec 20, 2014, 09:14:08
That's nothing like the groty turd you brought home. Damn I wish I had time for my own builds v.v
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 20, 2014, 18:51:48
I wish I had money, farkin Christmas...


Anyway paint soon and then finishing up the wiring.

I need new sprockets and chain as well.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: WhyNot on Dec 21, 2014, 09:52:50
Yea man......what a transformation.

Looking good.

I'm with you on the money part...............

I'm in the same boat with my little cb100.

But, I finally got the cylinder turned in for boring, hopefully that'll get me closer to buttoning up the engine.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: lukeglasso on Dec 22, 2014, 08:06:35
Yewww looking good Brod's, your going to be hooning round Benowa in no time.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 22, 2014, 08:39:33
Thanks guys. Not to much longer, just running this build on minimal funds haha. That and I spent some of them on another bike... woops.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Weldangrind on Dec 22, 2014, 21:38:21
Brodie, I have a matched set of '77 TS185 lower fork legs that are yours for the cost of shipping, if you want 'em.  It might be prohibitively expensive from Canada.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 22, 2014, 22:20:24
Thanks for the offer mate.

The lowers on this bike are all good, just the uppers that are pitted to hell.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: rufio on Dec 22, 2014, 22:59:51
I dig your Ts185 B!
I kept mine as the little dirt hustler that just takes its beatings over and over....only to start and run again another day. 
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 22, 2014, 23:52:38
Cheers.

Yours look nearly original. I can see them being a great offroad bike.
If I keep mine the next incarnation will be an offroad bike. Until then the ol XL will march on haha.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Weldangrind on Dec 23, 2014, 02:31:11
Thanks for the offer mate.

The lowers on this bike are all good, just the uppers that are pitted to hell.

I thought one of your lowers had a chunk out of it, just above the seal.  Am I mistaken?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 23, 2014, 02:36:41
Nope you are correct. Luckily most of the seal sits below the missing chunk.

I might take you up on it depending on how much postage is. But it would have to be a bit after Christmas. My wallet needs to recover haha.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Weldangrind on Dec 23, 2014, 03:10:18
Feel free to research the shipping options from Abbotsford, BC, Canada; let me know when you're ready.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Dec 23, 2014, 03:57:18
Cheers again mate.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Feb 03, 2015, 19:20:12
So I bought a house. It has no room for bikes, yet.

That is about where we are at with the build.

On another note, the Missus just got a slight payrise which means that my bike fund will be just that bit bigger.

I ordered a new sprocket set with the rear one tooth smaller than standard. A mate at work has offered to make a chamber for me but it has to be out of stainless. So I am not complaining there.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Weldangrind on Feb 04, 2015, 01:31:26
Congrats on the new house and Mrs. Brodie's raise.

I pulled those forks apart, and I could polish them for you if you like.  I have a polisher that makes it easy.  LMK.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Oct 08, 2015, 22:58:30
Ok I know it has been a hell of a long time since I updated this thread but I have been working on this bike again.

I managed to loose the front sprocket some how. I have gotten a crack in the tank welded and pressure tested. Found out the petcock leaked and bought a new one. Fitted the new rear sprocket. Gotten the exhaust mapped out to be fixed and ordered a heap of cheap parts.

All that is left now is wiring.... and paint. Ohh and a fork brace.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Oct 08, 2015, 23:00:50
I pulled those forks apart, and I could polish them for you if you like.  I have a polisher that makes it easy.  LMK.

Hey mate, thanks for the offer and sorry for the late reply.

I might give those lowers a miss, I am now trying to finish this build without spending any cash and using parts I have laying around. The fork seal seems to be holding up to my "tests" (bouncing up and down a heap on the bars"
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Weldangrind on Oct 14, 2015, 11:59:05
That's funny, I just found the lowers in the shop, and I was going to bring this back to the surface.

Let me know if you change your mind.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Mar 21, 2016, 21:35:57
Thanks dude.

And just to let people know this is not dead. I took her for a shake down. I need a better muffler that is for sure. It has bugger all low end but hits mid and takes off. Very happy with the pipe as power is where I wanted it.

(http://uploads.tapatalk-cdn.com/20160322/d31a9dbea4c7314c26463488937245d5.jpg)

Had to ride around with the choke on the whole time. Probably due to low idle setting and no air filter. Very happy with the take off so it can only be improved from here.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on May 01, 2016, 04:19:40
I rewired the ignition circuit and isolated it from the rest of the harness. Took her for another shake down today after I stuck some ATF in the forks.

Results of a through shakedown.

Needs a smaller rear sprocket. Way to much peak speed for a decent round town bike.
Carb needs a serious look at. Had problems with flooding most of the morning.
Felt like the clutch was slipping a bit.
Hard to change gears when the bike is not running.
Oil leaking from various areas. Think the engine will need all seals replaced.

That is about it.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on May 09, 2016, 19:52:18
I ordered a gasket kit. Looks as if it may come with seals. Going to strip the engine down and give the cylinder a hone and some new rings. Replace all the seals and clean out the inside.

I was planning to run ATF in the gearbox. Going to give it a shot before I do the rebuild to see if it helps any of the issues.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: cbrianroll on Nov 06, 2016, 18:11:14
Hey, is this project done?? My son has a 78? Suzuki 185 smoker he's gonna start working on, thinking of making it a bit more cafe Ish...or something. Am curious to see the finished product.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 06, 2016, 18:29:58
Not done yet mate, I have to many projects on the go and bounce from one to the other.

I currently need to rebuild the exhaust as all the thin spots got blasted open when I took it for a test ride.

I also need to replace the engine seals at some stage.

They are a good bike, just make sure the oil pump is in working order as it also lines the crank bearings.

I have considered using a flat seat but I still like the current look so I think I will keep it. If I recall correctly the seat is a Roc City seat.

Would love to see a build thread for your son's bike.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: cbrianroll on Nov 06, 2016, 19:36:06
(http://)He's 11 so......he gets distracted ha ha. I'll probably be doing a lot but that's fine! Like yours it's gonna be a little or no money job. It runs and drives, but it's just boring. Will probably do a thread, I'm bad so it'll be short. Bye the way...it's got more rust than it looks
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Nov 28, 2016, 18:14:36
So i tried to weld a new section on to the header of the chamber but it was not possible. Most of the chamber is no longer steel, but thick rust.

Looks like a hole new exhaust is in order.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Weldangrind on Dec 31, 2016, 21:24:04
Brodie, that could be a fun opportunity to play with a later-model expansion chamber, to see if you can wring out a few more ponies.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: harryahern76 on Jun 04, 2019, 23:42:54
Hi There,

I ended up finding this thread. I bought the project off Broady a few years back and have completed the bike since.

Few photos of the finished build are attached. Broady if you see this I'm having some issues with the 12v conversion, when I hit the headlight

my antigravity battery shits itself under the LED headlight's load, otherwise the bike charges the battery without it on. let me know your thoughts?

Happy to chat more about the build :)

Cheers,

Harry

Title: Re: '76 Suzuki TS185 "Roker"
Post by: advCo on Jun 05, 2019, 10:15:48
Awesome!
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Maritime on Jun 05, 2019, 11:07:49
Nice job.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: JustinLonghorn on Jun 05, 2019, 13:07:17
I can dig it, man.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Luugo86 on Jun 05, 2019, 14:06:16
Gnarly little bar-hopper.. well done man.
Title: Re: '76 Suzuki TS185 "Roker"
Post by: Brodie on Jun 05, 2019, 19:41:30
Awesome dude. Came out rad. Glad you finished it. I was only wondering about this bike the other day. Must be a hoot to rise with how light it is.

As for the battery. How big is it? What are the specs for the headlight?
Title: Re: '76 Suzuki TS185 "Roker"
Post by: harryahern76 on Aug 26, 2019, 01:32:02
Thanks everyone and yes so stoked its finally done.

Power band is crazy!

Battery is an Antigravity 4cell AG-401 14v, headlight is a 42w LED and only runs a low beam.

have a 6v to 12v reg rec but still doesnt charge the battery, I get around 25-30 minutes and electrics are completely dead.