T500 gear box shaft (input)

casperdog · Post by **casperdog** » Tue Mar 31, 2020 2:13 pm

Hi, the parts diagram shows the input shaft as one piece, but on the shaft on my bike there are 2 sleeves between 3rd and 4th gear which must mean the shaft has been built up. So...…. is it possible to split and re-build this shaft to make a good one out of a bad one.
I've just split my engine to do the oil level mod and check the condition of the gearbox and the only real wear / pitting is to 1st gear (one behind clutch bearing ???).
I planned buying a shaft with the probable shagged 4th and 5th gears (but with a decent 1st) and swapping the gears over.
Is this possible...any thoughts?
Thanks
Phil

dollydog · Post by **dollydog** » Tue Mar 31, 2020 2:42 pm

hi phil, if they're the same as the gt250 shafts, then yes. 2 of the gears on the 250 have a circlip affair that holds them in place. remove that and you can remove the gear

cheers, dd.

casperdog · Post by **casperdog** » Wed Apr 01, 2020 5:09 am

Hi, no circlips on this shaft I can see.
I've attached a couple of photos.
The two right hand side gears (1st and 2nd ???) are machined as part of the shaft.
The other 3 gears must have been built onto the shaft because the 2 spacers in between rotate freely on the shaft.
Are the other gears pressed / keyed on the shaft??
Just wondering if anyone had stripped one of these shafts before.
Thanks
Phil

20200401_111206.jpg

20200401_111225.jpg

dollydog · Post by **dollydog** » Wed Apr 01, 2020 3:07 pm

hi phil, if you get no joy on here, try this place https://ozebook.com/suzi/" onclick="window.open(this.href);return false; there's absolutely tons of stuff on the 500's, but whether it will sort you out only time will tell

cheers, dd.

casperdog · Post by **casperdog** » Fri May 22, 2020 12:02 pm

https://www.ebay.co.uk/itm/Suzuki-T500- ... 4298617425" onclick="window.open(this.href);return false;

Looks like this listing answers my question.
It appears other gears are simply pressed / shrunk onto the shaft.
Phil.

argo1974 · Post by **argo1974** » Sat May 23, 2020 5:15 pm

Those spacers were used on early T500's and disappeared later on. 3th, 4th and 5th gears are just press fit (not keyed).
You're on the safe side with 10 ton press, don't even try a 3 arm puller.

jabcb · Post by **jabcb** » Sun May 24, 2020 5:37 am

argo1974 wrote:Those spacers were used on early T500's and disappeared later on. 3th, 4th and 5th gears are just press fit (not keyed).
You're on the safe side with 10 ton press, don't even try a 3 arm puller.

Are the early & later T500/GT500 transmissions interchangeable?

Just bought a complete used 75 T500 transmission for my spares collection.
Have a 69 T500 that didn’t run when I bought it -- tranny condition is TBD. Can a use the 75 tranny in the 69?

argo1974 · Post by **argo1974** » Sun May 24, 2020 4:50 pm

They are all interchangeable throughout the T500/GT500 production run from 1968 to 1976. Later transmissions are more durable because of updated parts.
E. g. Suzuki used higher quality steel for some gears.

jabcb · Post by **jabcb** » Mon May 25, 2020 5:59 am

Thanks. Knew about the T500 tranny oil level fix but didn’t know they also improved gear durability.

kall399 · Post by **kall399** » Sun May 09, 2021 3:08 pm

Don't know how relevant this still is but I stripped three of these shafts to make one good one just heated it up with a hot air gun and pressed apart and back together no keys and the rotational position of the gears does not matter when assembling. Def. recommend a 10ton press my 6 ton was making some awful noises

T500 gear box shaft (input)

T500 gear box shaft (input)

Re: T500 gear box shaft (input)

Re: T500 gear box shaft (input)

Re: T500 gear box shaft (input)

Re: T500 gear box shaft (input)

Re: T500 gear box shaft (input)

Re: T500 gear box shaft (input)

Re: T500 gear box shaft (input)

Re: T500 gear box shaft (input)

Re: T500 gear box shaft (input)