Suzuki 2 Strokes

has anyone tried ep90 oil in the gearbox mine is whining badly on 20/50 - had it apart for inspection earlier in the year and all the gears looked fine with no signs of the case hardening breaking down at all and the bearings are all smooth running so cant really see what is causing it - it whines as soon as the clutch is let out - did nearly five hundred miles on it in the past fortnight and it doesn't seem to be getting any worse its just annoying

Most GL4, GL4/5, GL4+ or GL5 transmission oils work fine.
You can also try Castrol MTX 75W-140.

Since you said once clutch is let out this may help

https://www.ebay.com/itm/Suzuki-T500-GT ... SwsRBbSlvs" onclick="window.open(this.href);return false;

Sometime it is too long and needs to sanded a little shorter. There is also a mating thrush washer. Also the bushing in the clutch basket itself may be worn. Here is a NOS basket/driven clutch (pricey) ->

https://www.ebay.com/itm/SUZUKI-NOS-DRI ... SwzatbNdfR" onclick="window.open(this.href);return false;


I think the noise you here is the clutch assembly shaking about that spacer/bushing. Week point.

The GT250/T350 new OEM replacement Spacer today has the thrust washer integral with it. That fixes the shaking on those bikes since one stiff unit versus two separate parts. They didn't seam to do the same for t500.

Maybe someone could machine one up. Else renew what you have. or find low mile clutch assembly

good luck

edit > Maybe something like this will work as a new bushing in the basket?
https://www.motionindustries.com/produc ... u=07596660" onclick="window.open(this.href);return false;

Since you said once clutch is let out this may help

https://www.ebay.com/itm/Suzuki-T500-GT ... SwsRBbSlvs" onclick="window.open(this.href);return false;

Sometime it is too long and needs to sanded a little shorter. There is also a mating thrush washer. Also the bushing in the clutch basket itself may be worn. Here is a NOS basket/driven clutch (pricey) ->

https://www.ebay.com/itm/SUZUKI-NOS-DRI ... SwzatbNdfR" onclick="window.open(this.href);return false;


I think the noise you here is the clutch assembly shaking about that spacer/bushing. Week point.

The GT250/T350 new OEM replacement Spacer today has the thrust washer integral with it. That fixes the shaking on those bikes since one stiff unit versus two separate parts. They didn't seam to do the same for t500.

Maybe someone could machine one up. Else renew what you have. or find low mile clutch assembly

good luck

cheers - new bush fitted and milled to size and ---- exactly the same it whines as soon as its let out its been like it for thirty years - the original bush was worn and when stripped down last year had not been fully tightened as when it was fully tightened the clutch would not disengage - it doesn't seem to get any worse so I'll try it with gl4 transmission oil in it and see how it goes

just a thought malky, if you've had the clutch off, was there a washer behind it? there should also be one under the clutch basket. look for wear on the crank pinion and the rear pinion on the clutch body. you say it doesn't disengage when fully tightened up leads me to think there's a washer/spacer missing. i've had a couple of gt250 engines in where somebody hasn't fitted both washers and you can see plainly where the 2 pinions drive against each other, with the clutch being too low. it leaves a line round the crank pinion, about 3mm down.
cheers, dd.

hi DD,
been a while sorry but have only just come out of lockdown - when I fitted the new bush I also replaced the thrust washers and filled up with GL4 gear oil - only last weekend got to try it out,its quieter in as much as it doesn't seem to scream so much as the revs rise but the whine is still there - it shifts fine so think I'll just keep an eye on things for the moment but it doesn't seem to have got any worse over the past thirty years or so

Hi malky,

I just had a very unlikely thought on your issue. Race engines usually convert to straight cut Primary gears. They inherently whirrre compared to the helical cut std. Primary's. You might have a set of race spec. primary's fitted .

As I said, unlikely, but you might be lucky

Cheers Geoff

So does it whine when stationary? You said it whines as soon as the clutch is let out.

TP its quiet at idle and only starts to whine as the clutch is fed in - was out on it yesterday did about sixty miles its just annoying

As per your original question. Yes. I have used EP 90 in my 500J to the last 25yrs. Without any problems with gears or clutch.
Sean.

Sean,I'm using gl4/5 now and its working fine -still whines but nowhere near as bad as it was

'Steve Zodiac'?
Vardis ??

Fireball XL5.

Ah you must be a bit older. I was more Captain Scarlet. In my teen years I listened to the metal band Vardis featuring a different 'Steve Zodiac'. Cheers