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GT500 Cafe Racer
Moderators: oldjapanesebikes, H2RICK, diamondj, Suzsmokeyallan
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buzzer
- Around the block
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- Suzuki 2-Strokes: GT500, Harley Davidson V-ROD
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GT500 Cafe Racer
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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GT500 Café Racer build website https://jtccc.wordpress.com/" onclick="window.open(this.href);return false;
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Warehouse1001
Re: GT500 Cafe Racer
Are you rebuilding the crankshaft yourself?? That's quite an undertaking...
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rngdng
- AMA Superbike
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Re: GT500 Cafe Racer
Impressive, most impressive.....
Lane
Lane
If you stroke it more than twice; you're playing with it.
Too many bikes, too much time, ENOUGH SPACE, FINALLY! Never enough money.........
Too many bikes, too much time, ENOUGH SPACE, FINALLY! Never enough money.........
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buzzer
- Around the block
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- Suzuki 2-Strokes: GT500, Harley Davidson V-ROD
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Re: GT500 Cafe Racer
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!Warehouse1001 wrote:Are you rebuilding the crankshaft yourself?? That's quite an undertaking...
GT500 Café Racer build website https://jtccc.wordpress.com/" onclick="window.open(this.href);return false;
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buzzer
- Around the block
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Re: GT500 Cafe Racer
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?
GT500 Café Racer build website https://jtccc.wordpress.com/" onclick="window.open(this.href);return false;
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buzzer
- Around the block
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- Suzuki 2-Strokes: GT500, Harley Davidson V-ROD
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Re: GT500 Cafe Racer
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.
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.
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simmons1
- On the main road
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Re: GT500 Cafe Racer
Looking great!
T700, Africa Twin, Goldwing, Super Tenere, WR250R, TDR250, GS1000s, GT750, H2 750
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titan performance
- Expert racer
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Re: GT500 Cafe Racer
You've polished out the Suzuki emblem recess on the clutch cover?
Keeping old 2 strokes alive !
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buzzer
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Re: GT500 Cafe Racer
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!
GT500 Café Racer build website https://jtccc.wordpress.com/" onclick="window.open(this.href);return false;
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Vintageman
- Expert racer
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Re: GT500 Cafe Racer
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!
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!
Current registered, inspected, and running well 2 stroke motorcycles
74 GT250 (T350 upgrade),
76 GT250 (T350 upgrade),
71 T350,
70 T350,
74 GT380,
75 T500,
73 GT550,
75 GT750,
72 Yamaha DS7 (R5 upgrade),
77 Yamaha RD400 (Daytona Cyls),
73 Kawasaki H1 500
74 GT250 (T350 upgrade),
76 GT250 (T350 upgrade),
71 T350,
70 T350,
74 GT380,
75 T500,
73 GT550,
75 GT750,
72 Yamaha DS7 (R5 upgrade),
77 Yamaha RD400 (Daytona Cyls),
73 Kawasaki H1 500
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buzzer
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Re: GT500 Cafe Racer
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.
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.
GT500 Café Racer build website https://jtccc.wordpress.com/" onclick="window.open(this.href);return false;
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buzzer
- Around the block
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Re: GT500 Cafe Racer
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!
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joolstacho
- To the on ramp
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- Suzuki 2-Strokes: AS50, GS500, GT500, ex GSXR750 slabbie
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Re: GT500 Cafe Racer
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.
Vinyl Ester (Derakane) seems to be the go for resistance to fuels.
Nice work on this project.
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buzzer
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Re: GT500 Cafe Racer
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.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.
GT500 Café Racer build website https://jtccc.wordpress.com/" onclick="window.open(this.href);return false;
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joolstacho
- To the on ramp
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Re: GT500 Cafe Racer
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.
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.
