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PostPosted: Mon May 07, 2018 9:10 am 
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Still in the Driveway

Joined: Mon May 07, 2018 6:02 am
Posts: 5
Country: USA
Bikes owned: T500
I am restoring a 1970 T500 and have had it in daily use for the past two weeks mostly short trips and have 300 miles on speedo. The bike had not been used for a number of years but is mechanically sound, except as follows.

after about a week of riding I had to adjust the clutch and found the clutch release screw was screwed in about a quarter of a turn. I them adjusted that as the work shop manual suggests and immediately the motor developed a typical clutch rattle. So i opened up the clutch cover, honed the spacer to a difference of .003" and put it all back together. However i noticed that there was some play on the clutch cage even when the whole assembly was tightened up. Pull it apart again and micro the outside diameter of the spacer and inside diameter of the pressed brass bushing in the clutch cage and found about .007' of play. Could not find a new brass bushing anywhere so put it together again. The rattle is gone but there is still 'rumbling' when clutch is not engaged.

Is this something I just have to live with or should I try and get a new brass cage bushing made and fitted. This would be a bit costly.

I am also restoring 4 other T500 and microed 3 other spacers and all were the same outside and inside diameter. The pressed brass bushing were also all about the same inside diameter.

Any suggestions?


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PostPosted: Mon May 07, 2018 9:19 am 
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Expert racer

Joined: Mon Dec 01, 2008 2:52 am
Posts: 1109
Location: Manchester, UK
Hi and welcome.

Does the clutch rattle stop when you pull the clutch lever in, in neutral? If it does, and if there was no obvious sign of wear in the bushing (no gouges, score marks etc), I wouldn't worry. As long as it isn't grabbing or slipping, it should be fine. A T/GT500 is NOT renowned for low mechanical noise :)

The clutch will rattle on any 2-stroke because of the uneven idling. Especially on the 500 which has big old pistons and flywheels wanging around. Do change the gearbox oil if you haven't already done so.

_________________
1976 GT380 - wounded by me, and sold on
2006 SV650S. It's got cams, and valves, and stuff


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PostPosted: Mon May 07, 2018 10:21 am 
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Still in the Driveway

Joined: Mon May 07, 2018 6:02 am
Posts: 5
Country: USA
Bikes owned: T500
Thanks, what I suspected. It does stop the noise when clutch engaged in neutral.


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PostPosted: Mon May 07, 2018 10:42 am 
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Moto GP
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Joined: Mon Dec 13, 2010 4:32 pm
Posts: 3147
Location: southwestern Pennsylvania
Country: USA
Bikes owned: 69 T350 thru 75 GT750
If its bad enough that you want to do something about it, then see service bulletin General-15.
http://www.ozebook.com/compendium/techbuls/SerBulletin%20General%2010-18.pdf

_________________
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 73 project
T350 69, 71 & 72 project
T250 72
Honda 85 CB650SC & 86 CB700SC
Yamaha 75 XS650
09 Triumph Bonneville SE


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PostPosted: Tue May 08, 2018 3:08 pm 
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Still in the Driveway

Joined: Mon May 07, 2018 6:02 am
Posts: 5
Country: USA
Bikes owned: T500
Thanks for info!


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