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PostPosted: Thu Oct 11, 2018 3:02 pm 
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On the street

Joined: Thu Oct 11, 2018 2:27 pm
Posts: 28
Location: Stoke england
Country: United Kingdom
Bikes owned: Yr5 t500j
Hi all ive finally got one after years of looking ,mind you engines seized or frozen if you're in america,was told it may be through just standing but all the head bolts were loose and when I removed it the bore was very very rusty, both piston s cover the ports so there may be hope for the crank. Anyway there's a few bits missing and I'm wondering if other models use the same kickstart lever,passenger grab rail,and battery holder ? That's all for now but I'm sure to have lots more questions soon,hope i don't wear out my welcome ,cheers


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PostPosted: Fri Oct 12, 2018 3:52 am 
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To the on ramp

Joined: Fri Aug 11, 2017 7:09 am
Posts: 308
Country: england
Bikes owned: several gt250 ramairs
hi splant :D try here https://alpha-sports.com/suzuki_parts.htm" onclick="window.open(this.href);return false; for checking on parts numbers. just cross reference t500 and t250 or whatever, sure there are many parts interchangeable. get some photo's on so we can see what we're dealing with :D
cheers, dd.
ps, gt500/t500/gt250/t250 all the same kickstart lever :D

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GTS250 road registered. TS250 engine, Ramair frame.
GT250 big bang road registered. Both pistons fire the same time. USD forks.
GT285 road registered. Overbored - 58mm and TS125 +2 pistons fitted.
GT10 road registered. '65 T10 engine, GT250 frame.


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PostPosted: Fri Oct 12, 2018 11:55 am 
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To the on ramp
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Joined: Mon Jun 12, 2017 12:01 pm
Posts: 223
Location: Galveston County, Tx.
Country: USA
Bikes owned: '75 T500M since '93 Ridden it over 100,000 mi
Splant wrote:
........ Anyway there's a few bits missing and I'm wondering if other models use the same kickstart lever,passenger grab rail,and battery holder? .......


While your shopping for kickstart levers, heads up for you and others doing the same. Look to see if there is an uneven gap/reveal at the lever and pivot base....gap larger at the front than at the back. That is a sure sign that the pivot base shaft is split and just a matter of time before it breaks clear through and of course have a close look at the splines. I'll ask a seller to show a better pic or two of the splines if need be.

Bad design and almost every kickstart lever I've seen had the chrome nick off it where it has been constantly tapping the front footrest bracket. However slight, that doesn't help overtime.

Here are the ebay pics of a kickstart lever I recently purchased for another spare....price was low, more than fair....really surprised me. Looked good in the area I mentioned and upon receiving it, looks good. No tell tale sign of even the beginning of a crack. I always take the lever off the pivot base when I buy them to clean and grease the stop balls/spring and the main shaft. Also always have a brand new spare bolt handy and be sure and use a lock-washer AND a regular washer. This helps back off the special bolt a bit, keeping the first or second thread from digging into the pivot shaft.

Some came with grease nipples some did not. This one did not.

Image

Image


Here are some pics I took to show the bit of difference in the gap on a couple of different levers I have.

In order...good to just a matter of how much you ride and how much start and go.....i.e., the last one shown, from my experience would be a tip to have a spare handy just in case.

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Image

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Simply a bad design and pot metal too boot.

Here a few of my fallen soldiers over the past 25years/100,000 + miles I put have on my T500 in that time.

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From partszilla's fitment software..
https://www.partzilla.com/product/suzuk ... 2c6eeafdbb"

CMSNL also has 'fits what' software but I think you have to register with them.




and I think the grab bar was slightly different on some models, maybe curved forward more on one model than the other.... I don't really remember. Someone else should be able to chime in on that.

The battery box was the same for all models but the 'hold in' cross bracket varied, some had small tool bag holders (small 'saddle' added) on them.

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PostPosted: Sat Oct 13, 2018 2:17 pm 
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On the street

Joined: Thu Oct 11, 2018 2:27 pm
Posts: 28
Location: Stoke england
Country: United Kingdom
Bikes owned: Yr5 t500j
Thanks for advice,yes my kickstart s snapped there,been Stafford show today and got a battery box but there was nothing else there ,managed get the barrels off one with a bar screwed in the smaller barrel holes and a big bolt screwing down on the piston ,the other the worst with a
big sledge hammer and kept raising the barrel with various spacers .tried put photos on but they're 137 to many pixels wide and I'm not very computer savvy. Now to get these rusty gudgeon pins out .


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