1975 Suzuki T500 IT IS ALIVE! First start video 5/7/11
- Thread starter Wingspan
- Start date
abnab
gotta start somewhere
Re: 1975 Suzuki T500 Cafe build
Tons of potential there. Can't wait for your parts to all come in and we can watch it start taking shape. I love the look of the front forks with the fork boots. I hope you plan on keeping them that way. Makes for a cool retro cafe look
Tons of potential there. Can't wait for your parts to all come in and we can watch it start taking shape. I love the look of the front forks with the fork boots. I hope you plan on keeping them that way. Makes for a cool retro cafe look
Re: 1975 Suzuki T500 Cafe build
I do plan on leaving the boots in place.
The two things I'm really waiting on are my seat and rearsets. I'd like to get those in place before I go too much farther. I'd hate to refinish the frame then discover I needed to mod it further down the line. Also, my access to things like media blast cabinets is through my father who has been out of town on vacation. Once he's back I'll be able to start stripping and repainting the smaller bits.
I do plan on leaving the boots in place.
The two things I'm really waiting on are my seat and rearsets. I'd like to get those in place before I go too much farther. I'd hate to refinish the frame then discover I needed to mod it further down the line. Also, my access to things like media blast cabinets is through my father who has been out of town on vacation. Once he's back I'll be able to start stripping and repainting the smaller bits.
Re: 1975 Suzuki T500 Cafe build
My rearsets arrived a few days ago and now I'm not sure they're going to work. I've got two issues. First is that because I'm using the stock pipes I have almost no clearance for the shift arm and have yet to find one that will clear the muffler, kickstart lever, and engine case. Secondly, I'm 6'2" and even though the stock peg location puts my knees near my chest with the clubmans, they are actually more comfortable than anything else I can work out. To put the rearsets in a position where there is no lever interference also puts them much to high for me.
I'm now thinking about staying with the stock pegs and possibly going to higher bars than my current clubmans. Possibly drag bars or a superbike bend?
Next topic, what are everyone's thoughts on leaving most of the original patina in place? As summer is fast approching, I've given some thought to just giving the bike a good scrubbing, fixing what's broken, a shot of paint on the tins, and putting it back on the road instead of tearing it completely apart and doing a full resto. That would always be an option for later. Maybe call this just a V1.0?
My rearsets arrived a few days ago and now I'm not sure they're going to work. I've got two issues. First is that because I'm using the stock pipes I have almost no clearance for the shift arm and have yet to find one that will clear the muffler, kickstart lever, and engine case. Secondly, I'm 6'2" and even though the stock peg location puts my knees near my chest with the clubmans, they are actually more comfortable than anything else I can work out. To put the rearsets in a position where there is no lever interference also puts them much to high for me.
I'm now thinking about staying with the stock pegs and possibly going to higher bars than my current clubmans. Possibly drag bars or a superbike bend?
Next topic, what are everyone's thoughts on leaving most of the original patina in place? As summer is fast approching, I've given some thought to just giving the bike a good scrubbing, fixing what's broken, a shot of paint on the tins, and putting it back on the road instead of tearing it completely apart and doing a full resto. That would always be an option for later. Maybe call this just a V1.0?
Redrum Racer
Active Member
Re: 1975 Suzuki T500 Cafe build
I like that seat! I want to order one just like that for my T500. Do you have the model #?
I have the same color scheme
I like that seat! I want to order one just like that for my T500. Do you have the model #?
I have the same color scheme
Re: 1975 Suzuki T500 Cafe build
This thread has been dormant for quite a while, sorry about that. I don't spend much time working in the garage during the summer, too hot and I'd rather be riding or out doing other things. Summer is winding down though, and if this thing is ever going to see the street again it's high time I started making noise and getting dirt under my nails!
I started fitting my RocCity tail. It's still very much a work in progress. First I hacked off a few unneeded bits on the frame that were in the way. Next I trimmed and inch off the bottom of the tail all the way around so it would sit lower on the frame. I still have a few spots of interference between the tail, oil tank, and left side cover to work on. I also need to radius the front edge of the tail and possibly curve the tail up at the back a bit. I drew a few lines on one of the pics to show what I'm thinking.
No going back now!
Tail trimmed and roughly positioned, not attached yet:
Possible trim lines on tail? I like the idea of curving the back upwards. It would also give more wheel clearance:
This thread has been dormant for quite a while, sorry about that. I don't spend much time working in the garage during the summer, too hot and I'd rather be riding or out doing other things. Summer is winding down though, and if this thing is ever going to see the street again it's high time I started making noise and getting dirt under my nails!
I started fitting my RocCity tail. It's still very much a work in progress. First I hacked off a few unneeded bits on the frame that were in the way. Next I trimmed and inch off the bottom of the tail all the way around so it would sit lower on the frame. I still have a few spots of interference between the tail, oil tank, and left side cover to work on. I also need to radius the front edge of the tail and possibly curve the tail up at the back a bit. I drew a few lines on one of the pics to show what I'm thinking.
No going back now!
Tail trimmed and roughly positioned, not attached yet:
Possible trim lines on tail? I like the idea of curving the back upwards. It would also give more wheel clearance:
Re: 1975 Suzuki T500 Cafe build
I've got the tail mounted. I used some 1" square aluminum tubing for support between the tail and frame and a few bolts to hold everything tight. It turned out to be pretty simple. I also trimmed the back of the tail as I mentioned in my previous post. I think it's an improvement and will definitely give me the wheel clearance I need.
I just bought a set of rearsets. They're supposed to be bolt-ons but I want to mount them up to be sure. Then I'll go ahead and tear the bike all the way down and start refinishing things. I'm still struggling with colors and paint vs. powdercoat for the frame.
I've got the tail mounted. I used some 1" square aluminum tubing for support between the tail and frame and a few bolts to hold everything tight. It turned out to be pretty simple. I also trimmed the back of the tail as I mentioned in my previous post. I think it's an improvement and will definitely give me the wheel clearance I need.
I just bought a set of rearsets. They're supposed to be bolt-ons but I want to mount them up to be sure. Then I'll go ahead and tear the bike all the way down and start refinishing things. I'm still struggling with colors and paint vs. powdercoat for the frame.
Re: 1975 Suzuki T500 Cafe build
Looks great man! That thing has a really nice stance to it, and the profile is looking nice and slim, just like I like it!
Just my opinion, but anytime you have the opportunity to use powder on structural parts on a bike, go with it. Its a huge price of mind and will last you a lifetime. Trust me, sometimes redoing things really sucks!!!! :
Looks great man! That thing has a really nice stance to it, and the profile is looking nice and slim, just like I like it!
Just my opinion, but anytime you have the opportunity to use powder on structural parts on a bike, go with it. Its a huge price of mind and will last you a lifetime. Trust me, sometimes redoing things really sucks!!!! :
trackfiend
Active Member
Re: 1975 Suzuki T500 Cafe build
Very nice! I'm just starting on my GS450 and have been trying to decide on a tail. I really like how you have done yours, I may have to look into one of those myself.
Very nice! I'm just starting on my GS450 and have been trying to decide on a tail. I really like how you have done yours, I may have to look into one of those myself.
Re: 1975 Suzuki T500 Cafe build
Drag bars are a good compromise and look good to boot. That seat is sooooo much better than 99% of seats around here. It looks right.
The issue though is your legs - more specifically how bent they were in that early picture. With that amount of bend, your feet will lose circulation pretty quickly. Not so good.
With the seat mounted up and upholstered, it would be a good time to check again and that will help you to determine where the pegs need to go. I usually aim for just behind the swingarm pivot and just below the centerline of the swingarm.
Low seats make for less legroom and more bend at the knees which ideally should be around 90 degree bend. That may dictate how you modify the rear sets to make them work for you. it is probable that they will need to be spaced out (I iget that way at times :-[) and bent to clear the pipes which are quite wide on a stock bike.
Jemco in TX do a great set of pipes for the T/GT500. they will lose another 20 pounds from the build, add a few HP and make it sound way sharper. Oh, and they tuck in much better. Just a thought
There's a lot of useful info over at Sundial http://www.suzuki2strokes.com/forum/index.php
Drag bars are a good compromise and look good to boot. That seat is sooooo much better than 99% of seats around here. It looks right.
The issue though is your legs - more specifically how bent they were in that early picture. With that amount of bend, your feet will lose circulation pretty quickly. Not so good.
With the seat mounted up and upholstered, it would be a good time to check again and that will help you to determine where the pegs need to go. I usually aim for just behind the swingarm pivot and just below the centerline of the swingarm.
Low seats make for less legroom and more bend at the knees which ideally should be around 90 degree bend. That may dictate how you modify the rear sets to make them work for you. it is probable that they will need to be spaced out (I iget that way at times :-[) and bent to clear the pipes which are quite wide on a stock bike.
Jemco in TX do a great set of pipes for the T/GT500. they will lose another 20 pounds from the build, add a few HP and make it sound way sharper. Oh, and they tuck in much better. Just a thought
There's a lot of useful info over at Sundial http://www.suzuki2strokes.com/forum/index.php
Re: 1975 Suzuki T500 Cafe build
That early picture was just me screwing around. Those aren't the bars I'm using, I was sitting on the frame itself, and my feet were on the passenger pegs. I've got rearsets ordered, hopefully they'll be here soon and I can see how the riding position will be.
I plan on reusing the stock pipes, at least in the near-term. I know expansion chambers cut weight and add power, but to be honest I don't like the way they look on this bike and I actually prefer the sound of the stock pipes.
teazer said:
That early picture was just me screwing around. Those aren't the bars I'm using, I was sitting on the frame itself, and my feet were on the passenger pegs. I've got rearsets ordered, hopefully they'll be here soon and I can see how the riding position will be.
I plan on reusing the stock pipes, at least in the near-term. I know expansion chambers cut weight and add power, but to be honest I don't like the way they look on this bike and I actually prefer the sound of the stock pipes.
jlgace
Active Member
Re: 1975 Suzuki T500 Cafe build
Your bike is coming along nicely. I have one of these sitting in the garage [a 'down the road' project] so I will be following. Couple things I would like to pass on to you from my preliminary research which you may or may not already know. I'm also keeping the stock pipes. I just like the way the look, and I'm not taking mine on a track. Some mild porting and modifications to the baffles, which could also be removed and replaced with a solid piece of pipe depending on your noise tolerance, will perk up the machine a bit. You can also step up the carb size - I picked up a set of 34mm Mikuni flat-slides and they fit right into the original boots and it appears the throttle cable will work fine. On a safety note, everything I've read says the front drum has to go and the forks are mediocre at best and fairly soft - might be more of a concern for you being a bigger guy. Might want to keep an eye out for a 76 front end with the single disc. There are other compatible front ends out there as well, I think most of the GT series will fit - google is your friend. Good luck and good choice on a project foundation imho.
Your bike is coming along nicely. I have one of these sitting in the garage [a 'down the road' project] so I will be following. Couple things I would like to pass on to you from my preliminary research which you may or may not already know. I'm also keeping the stock pipes. I just like the way the look, and I'm not taking mine on a track. Some mild porting and modifications to the baffles, which could also be removed and replaced with a solid piece of pipe depending on your noise tolerance, will perk up the machine a bit. You can also step up the carb size - I picked up a set of 34mm Mikuni flat-slides and they fit right into the original boots and it appears the throttle cable will work fine. On a safety note, everything I've read says the front drum has to go and the forks are mediocre at best and fairly soft - might be more of a concern for you being a bigger guy. Might want to keep an eye out for a 76 front end with the single disc. There are other compatible front ends out there as well, I think most of the GT series will fit - google is your friend. Good luck and good choice on a project foundation imho.
