Suzuki 2 Strokes

I have a 1977 GT500 that i purchased in several boxes. It came with a service manual that is for a T500-II.

I am reassembling the front end, (that was removed when I got it) and the parts I have do not correlate with the service manual I have. Further google investigation I found another drawing specified for my 1977 GT500, and it further contradicts with the parts I have.
Here are all the parts I have to reassemble, Note: the bearing races and top bearing insterted in the frame already, and are supplied taper bearings


Here is the drawing specified for my bike



Closer inspection of the stem. it seem this is a stem from a older model? The drawing pictured above does not have the larger threaded shank or nut.
Also, there is not journal cut in the threads for the lock washer.



I am currently waiting for another service manual I bought off ebay two weeks ago, but not optimistic about it.

Thanks

I'm not the GT500 expert although I used to own one. The triple clamp and pieces I see there look correct. The stem goes through the headstock, the new tapered bearing is next, the washer and then the large nut are next. Then the upper triple clamp, thick washer and nut. I hope I didn't leave anything out.

You're in the right place....someone will get you going.



Lane

Thanks, however I forgot to mention that the washer does not fit over the threads.
I would expect to see a groove in the stem threads that the lock washer would lock into. Nothing there.

Also. The washer and nut are not even on the part diagram.

That odd looking washer looks more like it's out of the speedo drive gearbox on the front axle.

If it's supposed to be a lock washer teh tabs would need to be peened over when the nut is tight and it would need slots broached into teh stem to locate it.

tz375 wrote:That odd looking washer looks more like it's out of the speedo drive gearbox on the front axle.

If it's supposed to be a lock washer teh tabs would need to be peened over when the nut is tight and it would need slots broached into teh stem to locate it.

Ahhh. Quite possibly. I will look into that. Thanks

Looks like the head has been converted from ball bearings to the taper and some of these kits we have found out change the spacing between the top and lower triple clamps . I wonder if the PO didnt slide in a mystery washer to take up extra space they found they had when tightening the head together on the frame ? A test fit of the triple clamp assembly on the frame would answer this question .

For some strange reason Suzuki put the steering head bearings, races, and nuts on the handlebar page. It's the same way with my own bike.
http://www.partzilla.com/parts/search/S ... parts.html Also, your picture shows at least one ball bearing race as well as the tapered roller bearing. The ball bearings were stock SGP, tapered rollers who knows what. You must use the correct races for each bearing type. The upper and lower "inner" races (items 13) are press fit into the steering head.

kb75ts250 wrote:For some strange reason Suzuki put the steering head bearings, races, and nuts on the handlebar page. It's the same way with my own bike.
http://www.partzilla.com/parts/search/S ... parts.html

steering head bearings.jpg

Also, your picture shows at least one ball bearing race as well as the tapered roller bearing. The ball bearings were stock SGP, tapered rollers who knows what. You must use the correct races for each bearing type. The upper and lower "inner" races (items 13) are press fit into the steering head.

Yup

I got the parts manual I was waiting for and determined that there is another drawing (for a bizarre reason) showing the additional parts that have thrown me for a loop.

Using taper bearings. Measurements check out. And I ordered the parts I need from the dealer. I hope to have the front end assembled this week, then move on to the engine

Thanks everyone

Larry710 wrote: Using taper bearings. Measurements check out. And I ordered the parts I need from the dealer. I hope to have the front end assembled this week, then move on to the engine
Thanks everyone

Good choice going with the tapered bearings. They handle side loads much better than ball bearings do.

That washer with the two ears is from the speedo drive gear, someones been creative.