Suzuki S32-2 Olympian restoration

Maritime

Well-Known Member
Ha, I was just the fastest, there were others who would have if I was slower. Love this little bike.
 

sbaugz

DTT BOTM winner
Looks amazing ! Where did you find the chain guard I'm struggling to source anything close
I got the chain guard from Thailand and its a reproduction. All the original factory ones are rusted out. This cost me about $70 and about 4 weeks of waiting for shipping, and I had to modify it quite a bit to make it fit. I would say it was a "decent" reproduction part but it also had some issues. I got it powder coated to match the rest of the bike. Considering it was my only option, I think its fine.

https://www.ebay.com/itm/Suzuki-S10...757603?hash=item341d9759e3:g:XIEAAOSwz1peE0eS
 

Ibata

Member
I got the chain guard from Thailand and its a reproduction. All the original factory ones are rusted out. This cost me about $70 and about 4 weeks of waiting for shipping, and I had to modify it quite a bit to make it fit. I would say it was a "decent" reproduction part but it also had some issues. I got it powder coated to match the rest of the bike. Considering it was my only option, I think its fine.

https://www.ebay.com/itm/Suzuki-S10...757603?hash=item341d9759e3:g:XIEAAOSwz1peE0eS

Better than fine ! I love it. When you say Thailand, does that mean eBay or did you actually connect with someone there ? As for gas tank cap, do you know if it was ever to securely fasten , the one that I have just seems to sit on the tank but when I look at the tank I see no threading, so I was guessing maybe they designed them that way... One person told be that you flip the cap over , pour your oil in it , and put it in tank and it would be the correct ratio.
 

sbaugz

DTT BOTM winner
I posted the ebay link above. its also posted on your quoted comment above. Click the link above and you will see the auction.

Regading the gas cap- these are impossible to find new. The old ones shrunk and were notoriously loose. As a permanent solution, I had an aftermarket screw-in gas cap welded into my tank.
 

teazer

Well-Known Member
DTT BOTM WINNER
Gear lever could be re-chromed. The kickstarer too if it can be disassembled first. I had a couple from later Suzukis re-plated in Illinois. Show quality chrome takes a lot more polishing so it costs more. For a more original level of polish, most chrome platers should be able to do the job.
 

Ibata

Member
I posted the ebay link above. its also posted on your quoted comment above. Click the link above and you will see the auction.

Regading the gas cap- these are impossible to find new. The old ones shrunk and were notoriously loose. As a permanent solution, I had an aftermarket screw-in gas cap welded into my tank.
Sorry !! Totally missed the link ! Appreciate it ! As for the gas tank that would make sense with the rubber shrinking with age.
 

sbaugz

DTT BOTM winner
Gear lever could be re-chromed. The kickstarer too if it can be disassembled first. I had a couple from later Suzukis re-plated in Illinois. Show quality chrome takes a lot more polishing so it costs more. For a more original level of polish, most chrome platers should be able to do the job.
I may eventually do that. Unfortunately chrome is so expensive. With this build, I had a budget in mind and didn’t want to go over that. Which explains why I powder coated the fork lowers and rear shock mounts in “chrome” powder rather than having them chrome plated. It was the difference of $30 versus about $400. If this were a more valuable bike, I could justify the expense. With this build, I wanted it to look nice, run well, and not break the bank.
 

sbaugz

DTT BOTM winner
I took the bike for a short ride today. Went to the park to take some nice photos. It was about 40 degrees and windy, which is why I only took a short ride.

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sbaugz

DTT BOTM winner
Looks good out in the sun
one thing I noticed about the "sun" pictures- the chrome on the headlight bezel and tank shows its age for sure. On a positive side- the paradise shimmer powder coat has a really nice metallic shimmer to it. I was really happy with that color choice- it almost perfectly matches the stock suzuki blue except it has a very, very fine silver metal flake in it to add a little pop.
 

sbaugz

DTT BOTM winner
special thanks to Maritime for nominating me for BOTM this month, along with ridesolo for seconding the nomination. Its nice to know the build is appreciated. there is some stiff competition this month.
 

Ibata

Member
mocking up the bike after I got all the parts back from powder.
The taillight bracket, stand and peg brackets were powder coated black.
The engine cases and jugs were vapor honed.
new replica shocks.
polished up the side pieces on the tank.
New cables, plugs, coils.

Did you run with the original coil ? Mine seems to function now but the cables are in bad shape, was thinking I could get creative replacing the cables from the coil but haven't got into it yet .

View attachment 223226
 

Ibata

Member
I thought about doing that but its a strange design and doesn't seem to come all the way apart in order to allow it to be powder coated. I actually ordered a "replacement" unit twice from Thailand. Both times the parts did not fit. I also have tried to purchase a new or replica shifter lever too, but haven't had any luck. This bike is an early model and I have found that a lot of the parts are different than the later model had. I have been burned several times ordering parts for a S32, only to find that it doesn't fit this early model.

The other parts I had trouble finding were headers. These early model headers were larger diameter than the newer models. Twice I ordered headers and they didn't fit. (including the one time I went against my rule of NOT ordering from Paul Miller- he was the only person who had them- turned out he labelled them wrong and they didn't fit- I had all sorts of issues trying to get him to let me return them, and eBay had to intervene)
You are so correct ! I just ordered a Kickstart pedal from Thailand and now you have me worried ! Hope it fits .

I'm studying the parts diagram now , and noticed on the supplement to the shop manual they mentioned they also changed the Piston rings/pistons at some point from squarish rings to more tapered ones . Did you change any of the engine gaskets ? Listing rings ?
 

Ibata

Member
You are so correct ! I just ordered a Kickstart pedal from Thailand and now you have me worried ! Hope it fits .

I'm studying the parts diagram now , and noticed on the supplement to the shop manual they mentioned they also changed the Piston rings/pistons at some point from squarish rings to more tapered ones . Did you change any of the engine gaskets ? Listing rings ?
https://www.ebay.com/itm/380186777070
this the Kickstarter , pay twice it's worth in shipping but still seems to be affordable and the best option.
 

sbaugz

DTT BOTM winner
https://www.ebay.com/itm/380186777070
this the Kickstarter , pay twice it's worth in shipping but still seems to be affordable and the best option.

I am afraid I do not have good news for you. The kickstarter that I purchased used the exact same stock photo as your eBay auction (although its a different seller). The description is also the same as yours. Unfortunately it did not fit. You may get lucky.

I discovered some info on these bikes from a FB two stroke group. Evidently there were early and later versions of this bike. There were some significant changes throughout the years. maybe your kickstarter will fit.

regarding your other questions- I bought some aftermarket coils on eBay. They came with coils, plug wires and caps. Total was $15 per coil. Here is the link: https://www.ebay.com/itm/264021976115

Finally, regarding your rings, pistons, gaskets questions. I changed everything. The gaskets fit fine. I bought them from partzilla. I do not think those changed through the years. The pistons and rings I had laying around from another parts stash purchase on some other suzuki parts. The other major change were the exhaust pipes and headers. The early and late models are different. I ordered two different left headers and they both were wrong. I had to return them both.
 

Ibata

Member
I am afraid I do not have good news for you. The kickstarter that I purchased used the exact same stock photo as your eBay auction (although its a different seller). The description is also the same as yours. Unfortunately it did not fit. You may get lucky.

I discovered some info on these bikes from a FB two stroke group. Evidently there were early and later versions of this bike. There were some significant changes throughout the years. maybe your kickstarter will fit.

regarding your other questions- I bought some aftermarket coils on eBay. They came with coils, plug wires and caps. Total was $15 per coil. Here is the link: https://www.ebay.com/itm/264021976115

Finally, regarding your rings, pistons, gaskets questions. I changed everything. The gaskets fit fine. I bought them from partzilla. I do not think those changed through the years. The pistons and rings I had laying around from another parts stash purchase on some other suzuki parts. The other major change were the exhaust pipes and headers. The early and late models are different. I ordered two different left headers and they both were wrong. I had to return them both.
Thanks for the info , I have an early model for sure, thin exhaust pipes 1965 , I noticed your front fender looks different than mine , your actually looks alot different then many I seen, it's pretty rad actually ! I believe yours is still stock though because I seen one ad that appears to have a style that looks like yours.

Prior to his I have only done upgrades on my modernish dual sport dr650. So getting into the engine is new for me but I think I picked a fairly primitive motor to learn from. Assuming my block cyclinders look good , can I just light hone and replace with oem piston rings ? Some people online had me confused saying needing oversized rings if you hone. Obviously if I bore I need to go with larger pistons but I'm trying to just hone and use oem rings .
 

sbaugz

DTT BOTM winner
Thanks for the info , I have an early model for sure, thin exhaust pipes 1965 , I noticed your front fender looks different than mine , your actually looks alot different then many I seen, it's pretty rad actually ! I believe yours is still stock though because I seen one ad that appears to have a style that looks like yours.

Prior to his I have only done upgrades on my modernish dual sport dr650. So getting into the engine is new for me but I think I picked a fairly primitive motor to learn from. Assuming my block cyclinders look good , can I just light hone and replace with oem piston rings ? Some people online had me confused saying needing oversized rings if you hone. Obviously if I bore I need to go with larger pistons but I'm trying to just hone and use oem rings .
Does it have good compression now? If compression is within spec, you technically don’t have to do anything. Just put the pistons and rings back in- making sure you remember right from left

I have gotten a lot of expert info from the two stroke FB sites. I’ve also done a lot of research on this bike. The 1965 models and some early 1966 models had the large flare out steel fenders, full length fork covers, single cam brakes up front, absence of a steering damper, larger inner diameter headers - all these are like mine has. The late models had the small chrome or painted fenders, short 1/2 length fork covers with exposed springs and fork gaiters, duel cam front brakes, smaller ID headers, steering damper and a few other changes. It sounds like maybe your 1965 has some late model parts. Most likely mine was technically a 1965 but was sold as a 1966. In the 1960’s, they would frequently title a vehicle based on when it was sold, rather than when it was made. my Serial number is low, so it’s likely a leftover from previous year.
 

sbaugz

DTT BOTM winner
thanks to those who voted for my bike, making it the May BOTM. I appreciate the praise.
I put about 50 miles on the bike this past weekend. It runs really well and I feel like I have all the kinks worked out. Now on to my next project.
 

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