Suzuki 2 Strokes

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?

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.

Thanks, what I suspected. It does stop the noise when clutch engaged in neutral.

If its bad enough that you want to do something about it, then see service bulletin General-15.
http://www.ozebook.com/compendium/techb ... 010-18.pdf

Thanks for info!