Suzuki T500 Engine Question

johnu

johnu

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Need to get the cylinders bored on my T500 engine but not sure what the piston to bore clearance should be. In the shop manual it says max clearance should be 0.006". I need to know min and max clearance, 6thou max doesn't sound right to me.
 
As the cylinder heats up it gets tighter a bunch of clearnce and new rings is way way better than not enuff. After market forged piston need even more room to grow keep them loose. so throw those factory number out and use the piston manufactures specs plus after the motor together you will need to let the jugs come up to temp befor ya run the bike hard
 
It's in the book.
just take a look at stock cylinder bore, stock piston size, take the little number away from big number and you get clearance. you can also get average clearance plus 'blueprint' clearance by using min/max sizes
 
Wiseco come with a chart of recommended clearance for different applications, usually going to be around 0.004"~0.006" if they are the 'old' Wiseco's lot less for new ones
 
Thanks for the replies. I wish I had Wiseco pistons but I had to go for the "el cheapo" $80 ebay pistons which are actually supposed to be pretty good. In the book it gives the cylinder bore size but not the piston size, it just says 0.006" clearance for the piston which I'll assume is right but it doesn't give any tolerance +or-.
 
Depending on the actual alloy, cast pistons run tighter clearances than forged by a few thou.
I wouldn't bore to 0.006" clearance, see what clearance similar year TM/RM250 uses
 
Swivel said:
If you are running Wiseco forged pistons they run a different clearance to standard cast ones.....
Click to expand...
thats what i just said dick
 
I don't have a manual for that bike but I'd expect it to be around 0.0015" or slightly more for stock cast pistons.
 
OK, I spend a bunch of time looking for information, can't find any for T500 but, I did find info for air cooled PE250 single
That uses 0.06mm~0.07mm which is about 0.0024" to 0.0028" so your probably looking at just under 3 thou piston to cylinder clearance
I would go two to two and a half thou, your not building a race motor
I haven't seen T/GT 500 manual for years (Don't even remember owning one, but, my brother tells me I sold it to him so I must have ??? )
 
crazypj said:
OK, I spend a bunch of time looking for information, can't find any for T500 but, I did find info for air cooled PE250 single
That uses 0.06mm~0.07mm which is about 0.0024" to 0.0028" so your probably looking at just under 3 thou piston to cylinder clearance
I would go two to two and a half thou, your not building a race motor
I haven't seen T/GT 500 manual for years (Don't even remember owning one, but, my brother tells me I sold it to him so I must have ??? )
Click to expand...

Thanks for the help (all of you) I appreciate it. I just found some info on a totally obscure website which confirms your info, it said 0.065mm - 0.075mm. Sounds like you've been around a lot of Suzuki's . Not a race motor but trying to get 55hp out of it.
 
That should be real easy, set of expansion chambers and 36mm VM carbs to RM specs
I would see if you can find porting specs for the 72~73 TM 250 (pre- case induction motors)
 
Porting is already done by a member on here (zooke581). I am not sure if I am going to make my own chambers or buy them from Swarbrick Racing. I have to get 0.020" taken off the heads also.

Would 36mm carbs fit on to the original intake rubber boots?
 
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