1975 Suzuki T500 IT IS ALIVE! First start video 5/7/11

[Wingspan]

Re: 1975 Suzuki T500 Call it whatever you want!

how much did that pretty charging system cost?
i think i want to go that way

Here's the link to the system on Powerdynamo's site:

http://www.powerdynamo.biz/eng/systems/7261/7261main.htm

Price is 311 Euro, so roughly $430 + shipping depending on the exchange rate.

 

[Wingspan]

Re: 1975 Suzuki T500 Call it whatever you want!

Let's get into the motor...

Say goodbye to those points, they won't be returning to the party. The new electrical system arrived from Germany yesterday:

The heads came off without too much drama:

EXCEPT for one bolt, which came out just a bit too easily...No threads, and the bolt appears to have been held in place with some sort of (now crumbling) glue!!! Grr....why do people do this crap?

There should be threads in this hole (center of pic) but I don't think they've been there for a long time:

Excuse me mister...your pistons are showing. ;D

The clutch cover screws hung on for dear life. Had to run to the hardware store for an impact driver. No problems after that. I could have used it sooner in a few other spots.

Clutch:

I don't know why, but I love opening up nasty old engines. They look so gross on the outside, but so pretty on the inside!

To be continued... ;D

 

[teazer]

Re: 1975 Suzuki T500 Call it whatever you want!

Oh the joy of opening up years of neglect on the outside to reveal those clean shiny nicely designed internals. All too often, they look as bad on the inside. You got lucky no one has made a mess of it.

I see a Helicoil 8mm repair kit in your future. Available from NAPA or probably from any tool place.

 

[Royal]

Re: 1975 Suzuki T500 Call it whatever you want!

Where did you get that huge tray the motor is on?

Cheers,

R.

 

[Wingspan]

Re: 1975 Suzuki T500 Call it whatever you want!

Oh the joy of opening up years of neglect on the outside to reveal those clean shiny nicely designed internals. All too often, they look as bad on the inside. You got lucky no one has made a mess of it.

Yep. Aside from the one stripped head bolt, it doesn't look like it's been monkeyed with. Judging by the level of corrosion on the screw and bolts, I'd say this is the first time many of them have been out.

I see a Helicoil 8mm repair kit in your future. Available from NAPA or probably from any tool place.

Already have it. I tend to keep things like this on the shelf. I think I've repaired more 8mm threads than any other and this kit has already paid for itself many times over.

Where did you get that huge tray the motor is on?

Cheers,

R.

Any autoparts store should have them. I think I got this one from the local Autozone a few years ago. Pretty handy thing to have in the shop.

 

[sparkymoto]

Re: 1975 Suzuki T500 Call it whatever you want!

Great progress Mark! Looks like you're keeping a good pace for this project. I'm really looking forward to seeing how the engine spruce up goes for you.

I had a few hours to work on the T500 this past weekend. Got it somewhat stripped down and drained. The carbs are pretty gunky so i'll jump on that soon. The complete engine gasket set should be here today or tomorrow. The phillips bolts on the the cases were mean to me as well. Nice and soft too I'd like to replace those with hex heads. I quit working on it when the clutch cover wouldn't come off after finally removing the bolts. Also noticed the oil level bolt has been sheared off by the P.O. :

 

[reelinfeele]

Re: 1975 Suzuki T500 Call it whatever you want!

damn PO's. good luck, that looks like a very nice platform to start with.

 

[Wingspan]

Re: 1975 Suzuki T500 Call it whatever you want!

Great progress Mark! Looks like you're keeping a good pace for this project. I'm really looking forward to seeing how the engine spruce up goes for you.

I had a few hours to work on the T500 this past weekend. Got it somewhat stripped down and drained. The carbs are pretty gunky so i'll jump on that soon. The complete engine gasket set should be here today or tomorrow. The phillips bolts on the the cases were mean to me as well. Nice and soft too I'd like to replace those with hex heads. I quit working on it when the clutch cover wouldn't come off after finally removing the bolts. Also noticed the oil level bolt has been sheared off by the P.O. :

The case screws were a pain on both sides. Butter soft! I'm going with hex heads on the rebuild also, most likely stainless.

 

[Wingspan]

Re: 1975 Suzuki T500 Call it whatever you want!

I haven't had a lot of time to work on the T500 over the past few days, but I did crack it open this morning.

 

[Wingspan]

Re: 1975 Suzuki T500 Call it whatever you want!

Crankshaft out. I'll be sending this out to be rebuilt with new seals.

Cases look pretty clean inside. Not much gunk or shavings...and no big unidentifiable pieces (always a good thing):

Bare cases ready for cleaning and paint:

Some organization required... ;D

I've got a buddy at work who has a nice set of bore gauges and he offered to measure the cylinders. Once I have a better idea of their overall condition I can decide if a simple hone and new rings will do or if I need to go oversize. Then I'll box up the crank and cylinders and send them out.

 

[Wingspan]

Re: 1975 Suzuki T500 Call it whatever you want!

Small update. Hopefully I'll actually make forward progress someday! So far all I do is take things apart and buy parts. ;D

Got my cylinders back from being measured. They're just a smidge outside spec, so I've ordered a new set of 0.5mm over pistons and rings. New pins, clips, and bearings are on the way as well. I'm waiting on a quote from the shop, then I'll sent the crank and cylinders off to have all the work done.

The bike takes up less floor space this way...

 

[teazer]

Re: 1975 Suzuki T500 Call it whatever you want!

And while it's up there it's easy to see where the two extra frame tube could go.........

 

[Streetfighter89]

Re: 1975 Suzuki T500 Call it whatever you want!

I really like your attitude concerning major perfomance mods and stuff like that!

Well the brake disscusion was some time ago but I want to state my opinion on that. I think a good mantained drum with modern compound shoes on it would brake much better than the "less friction"-stainless rotors, I'm really concerning to do a drum brake conversion on my GT 250 with a T 500 drum, all ready had spied out ebay a while ago fopr donors.

By the way, Titans are awesome bikes, not so long ago I had the chance to snap one for cheap (of course in bad shape but with potential) but I think I'm a one-motorcycle-man.

Keep up your good work!

 

[Wingspan]

Re: 1975 Suzuki T500 Call it whatever you want!

I really like your attitude concerning major perfomance mods and stuff like that!

Well the brake disscusion was some time ago but I want to state my opinion on that. I think a good mantained drum with modern compound shoes on it would brake much better than the "less friction"-stainless rotors, I'm really concerning to do a drum brake conversion on my GT 250 with a T 500 drum, all ready had spied out ebay a while ago fopr donors.

By the way, Titans are awesome bikes, not so long ago I had the chance to snap one for cheap (of course in bad shape but with potential) but I think I'm a one-motorcycle-man.

Keep up your good work!

Thanks. I think the important thing to remember when we get into these discussions is that we're all building our own bikes. There is no single "right way" to do things. Some people are focused only on performance, some only on looks, most of us are somewhere in between. It is entirely possible that once this bike is rolling I'll find I don't trust the stock drum. If that turns out to be the case then I'll seek out an alternative. I already keep an eye on ebay for Suzuki front ends for swap, both disk and 4ls drum. If I found one in good shape and at a reasonable price I'd probably go for it.

One motorcycle man? What's that??? ;D

In other news, the UPS guy delivered my new pistons and rings. The new pins, bearings, and clips also arrived. All parts are NOS Suzuki items. I'll get things cleaned and boxed up this weekend and ship the crank and cylinders off to Bill Bune (www.billbune.com) on Monday.

 

[Blacktopbandit]

Re: 1975 Suzuki T500 Call it whatever you want!

I've been following this build with the giddiness of a kid with a new toy. I was looking for a new project and after seeing the way your T500 is turning out i think I've found my new direction. Cant wait too see this one finished.

 

[Wingspan]

Re: 1975 Suzuki T500 Call it whatever you want!

Spent some time this afternoon getting to know my new buffer. Not a very exciting job, but rewarding when that shine starts to come up. Still a lot of polishing to do.

 

[JoeTee]

Re: 1975 Suzuki T500 Call it whatever you want!

Just read thru your thread, great stuff man. Looking forward to seeing it come together.

 

[Wingspan]

Re: 1975 Suzuki T500 Call it whatever you want!

Thanks. ;D

 

[Wingspan]

Re: 1975 Suzuki T500 Engine rebuild underway

Spent some tome today cleaning up the big engine bits. Not finished yet, but getting there.

Now to get the crank and cylinders boxed up and ready to ship out tomorrow.

 

[Wingspan]

Re: 1975 Suzuki T500 Engine rebuild underway

No progress, but more parts news. The crank and cylinders went out in the mail yesterday.

Today the DHL guy dropped off a big package from the UK...WHOOO HOOOO! My expansion chambers are here!

These are from Titan Performance, the same guys who made my rearsets. They're polished stainless steel and look great! MUCH lighter than the stock exhaust too. Can't wait to hear them.

I also got a new oil plug. The T500's stock oil filler plug is a rather cheesy rubber stopper. After loosing a plug (and coating the rear tire with oil) on one of their own bikes, the Titan Performance guys started selling their own machined aluminum plug.