Suzuki 2 Strokes

Hi Guys, thanks for letting me join, I am new to the forum and thought I would post about my Café Racer build from a 1976 Suzuki GT500 I recently bought in bits. For the full story have a look at my web site, but for now here are a few pictures!

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Are you rebuilding the crankshaft yourself?? That's quite an undertaking...

Impressive, most impressive.....


Lane

Warehouse1001 wrote:Are you rebuilding the crankshaft yourself?? That's quite an undertaking...

Yes, its done. Not too bad a job in the end although i did not part the crank webs to remove the con rods as these were OK. Main point was to replace the centre seals which had gone hard after 40 years!

I want to fit expansion pipes, but I like the way some bikes have them tucked in to give better ground clearance... can I still use the centre stand if I do this? anyone got a picture of tucked in pipes with a side stand?

Engine is now complete. The crank build went well, less than .002" run out on the dial gauge after I had finished.

The final polish of the cases can be done when I do the final build as I am doing a dry run before I paint the frame to see that everything fits and I don’t need to weld on any brackets! The cases took a lot of polishing as there were some major pitting... I had to replace the alternator cover with one off a T500.

Looking great!

You've polished out the Suzuki emblem recess on the clutch cover?

titan performance wrote:You've polished out the Suzuki emblem recess on the clutch cover?

Yes, i polished it out. The recess where the stick on emblem sat was badly pitted, including the edge, which looked a mess. I used a DA sander to take it down to remove the pits, which took out the recess.

The altenator cover was so bad i had to replace it!

buzzer,

You definitely have skills.

I see on your website, you used a three prong puller to remove GT500 crank bearings. But how did you get the bearing started? The puller ends look too thick and the bearing looked real close to the crank web and not much space to get puller in between to start things moving?


When you checked your crank for true I see you used the Web wheels not the crank ends. When I trued a GT250 crank that way (webs) every time I got near the rod big end pin the gauge moved a strong +0.001"... but for only about 60 degrees. I realized this was the rod pin interference with the web causing the web to expand a little. Well the gt250 web is much smaller than the GT500.

Good stuff!

I moved the bearings the first 5mm off the shaft by using a couple of long pry bars in the "O" ring grove and levering the bearing up. Here are the bars I use. In fact, these are one of the most useful tools in my box! I seem to use these all the time when working on cars and bikes!

The dial gauge is shown measuring the crank webs out of interest... the trick is of course to get the shafts all in line, this is what needs to be accurate.

Bit of an update. I have been busy modifying the frame, adding some bracing, and also making a tank and some clip-ons. with a bit of luck I should have the wheels back tomorrow. The tank is not the final shape, but its getting close!

Good to see you doing a 'lost-foam' (I assume) fibreglass tank. What chemistry resin will you be using?
Vinyl Ester (Derakane) seems to be the go for resistance to fuels.
Nice work on this project.

joolstacho wrote:Good to see you doing a 'lost-foam' (I assume) fibreglass tank. What chemistry resin will you be using?
Vinyl Ester (Derakane) seems to be the go for resistance to fuels.
Nice work on this project.

Hi, I should have said tank cover... I will be making an alloy tank which goes under this as I don't want the hassle of a glass tank. I thought it would be easier to make the cover first.

Not a bad move. Just in case you don't know about the lost foam method...
You can lay up the 'glass right over the foam, you don't really need a sophisticated mould release system.
So once the 'glass has fully cured, you can just dig most of the foam out then use something like petrol to melt out rest of the foam. Yep it's messy, but saves the releasing process.