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Project 1974 Suzuki t500

Discussion in 'Other Projects - Other Bikes (non 250's)' started by kiffsta, Sep 23, 2018.

  1. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    My two cents, again. The cylinder is squeezed from two sides, thus the stress on that point. The stress on yours has been relieved by the crack. Brazing it will be fine.
    Cutting it off is the other alternative. Better than leaving it there with a crack in it.
     
  2. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    I'm pretty sure all the Yamaha's from the mid/late 70's and onward's PW, YX, IT, DT's all had that bridge cut out of them standard
    I'd be chopping them out on both barrel's and deburring the edge's
     
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  3. Wozza

    Wozza Active Member Premium Member Contributing Member

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    As above cut em out cleanup the edges..Not like its going to be thrashed every day.....Then keep an eye out for a matching later barrel or sell it on...
     
  4. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    I don't think you would be doing any harm to the barrel by removing that piece as it would be below the piston travel and not really doing anything support wise. Most other Jap barrels I've worked on don't have the bottom bridge part to them and look just like the cut one.
     
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  5. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    thanks for the feedback, I called my engine guy , I have emailed him the pics and his is going to cut them.
     
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  6. Duggs63

    Duggs63 Well-Known Member

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    Very cool project! Love seeing 2Ts brought back to life. Keep up the good work Kiffsta
     
  7. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    While I am waiting on the crank, barrels and pistons to get done, I thought I might adress the ignition coils , the ones on the bike are incorrect and held on with tape , I was talking with Chris from netbikes and he said there is a stash of Bridgestone coils in the us for $50 a pair and they bolt straight on , i now have a set winging their way to me .

    2E751A61-01AB-465B-B70F-B4DD504A5F4B.png DC47C1E3-C9C2-46D3-AA5B-EB110EB2ADCE.jpeg
     
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  8. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Good news, rods are in good shape so I should have the crank back early next week, My coils have arrived from the US of A

    I need to track down a Haynes manual for a t500 in Australia, doesn’t seem to be any online

    8EA8C39D-0586-46CE-B3F6-CC5AFB50D8A9.jpeg
     
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  9. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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  10. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Thanks mate , That one is in my saved list, I was hoping to find one locally , Haynes have some stuff published on-line but the Suzuki twins book isn’t offered
     
  11. WEREWASI

    WEREWASI Member Premium Member

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    143 pages of stuff put out by Suzuki MotorCo that i have could be same stuff as My67xr has.
    Have rung Guy at Inverell restorers club who has just done seals on his T500 but he is in Pt Macquarie and will send me stuff he used for his teardown, when he gets home.

    Since I suspect that my seals need doing I'm happy to go halves on a Haynes manual
     
    Last edited: Oct 20, 2018
  12. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    The crank is back with all new seals and is ready for installation

    7836430C-2BDF-4966-874D-E6B78690658E.jpeg
     
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  13. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Barrels are back , new wisco pistons and rings have arrived as well , just waiting a few bits to arrive from Suzuki then we will start reassembling

    77BD4A1A-2760-4808-BFFF-783E65BE3853.jpeg 0BFEB06E-6ECC-4F55-90B3-065B9224AC36.jpeg 92B422D0-89B8-4EFF-BC34-0C8119B925A0.jpeg 3985CFDD-687D-4840-97E0-FEEC01539F6F.jpeg
     
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  14. Andych

    Andych Well-Known Member Premium Member

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    Those Wiseco’s are a nice bit of gear aren’t they. Did you have the bores done to suit the pistons or just go on the oversized figures?
    I will be having the 350 bored to suit the piston and the Wiseco clearances... just to be sure
     
  15. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    My barrels were already 1mm over, there were some slight marks from siting so they were given a hone first, the feedback I got was that the bore on one side was slightly larger than the other , we had chosen wossner pistons, but if I wanted them I would have to go 1.5mm over as the bore measurements were borderline on one, instead he suggested wisco’s as they could be slightly larger than wossners which turned out to be true. So I am still on 1mm over which is great, 2 more lives in these barrels.
     
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  16. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Today was engine assembly day for the t500, I asked a mate of mine who did his time as a Suzuki mechanic assist with the reassembly, gearbox went together quite easily and I attempted to get as much info out of him as he assembled it. We came to fitting the crank and he attempted to rotate once it was in the lower case , what we found was that it was binding up against the case, he used a paint pen to mark the crank web then rotated the crank in the case so he could work out where it was rubbing. So reassembly has stopped and I need to send me crank back for some very minor rework.

    Well, that’s 2 steps forward and 1 step back. On a positive note, the gearbox is all back together.

    7362B143-018F-4B13-92E7-82C2A0BF9235.jpeg 7A161602-24AE-4BFB-B1DC-CD50787B8E52.jpeg 67296E13-FBC9-42DC-A783-241D7A52BD2B.jpeg 1666D563-06EB-4CE1-99C7-55C0C599B68A.jpeg
     
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  17. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Well that'd rot your socks. How the hell does that happen unless the rod assy is wider than the previous set?
     
  18. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Everything was within spec so nothing was replaced except for the seals. I messaged the guy who rebuilt it and he came around this morning and took it away with my case and sorted it , I collected it today, it is busy in the shop so no time to play today.

    On a brighter note , one of my customers sent me this after seeing the t500

    10647F47-8EAA-47A7-9E83-84B0ECF8A80F.jpeg
     
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  19. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    I ponied up a few dollars and purchased a Newtronic electronic ignition system for the T500 , these kits are cheap and have alot of benefits over the stand points system.

    newtronic_kit_lg.jpg newtronicbox.jpg
     
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  20. beano

    beano Well-Known Member Premium Member

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    I’m doing up an old xs650 at the moment and have one of these, they’re basic but allow you to use the old coils etc, much handier than messing around with points and condensers!!
     

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