Suzuki T500 Restoration/Cafe Project

[celt_rock]

I don't know why I was so surprised that the engine was so clean inside.
Then again, I don't entirely know what I'm looking at or looking for. Looks like
a little bit of water got in under the left crank as the oil is a little milky but the
crank isn't pitted anywhere or showing signs of bad corrosion.

06 Crankcase.jpg

08 Gears.jpg

09 Gears.jpg

This screw holding the kick lever down is just about impossible to remove. I ended up drilling out the
3 screws that held on the stator assembly, I don't want to do that here...

10 Kick.jpg

Look at the shape those teeth are in! Much better than the ones in my head

11 Teeth.jpg

[celt_rock]

After months of tracking down parts, de-rusting, de-greasing, re-painting, fabricating... it's starting to take shape.
Next step is to re-assemble the engine, refurbish the carburetors and re-do the wiring harness.

I decided that, while I couldn't cut this bike up into a cafe racer, I could at least customize the bits that weren't
already original. The tank is some form of Chrysler Metallic Gray, I'll most likely get a cafe style padded seat like
those ones from Vietnam though I really wanted to put the battery and electronics under the seat.

Mine didn't come with a battery box or air box so I'll probably scan e-bay for a battery box so I can locate my
evo battery and electronics there.

[celt_rock]

Finally starting to button up that engine... man I shouldn't have let so much time go by... it's amazing what I've forgotten
already!

[celt_rock]

Not that anyone's paying too much attention but I've certainly not stalled in my project. The engine is buttoned up and I've started "dry fitting" the parts all together. Here she is now;

T5002.jpg

T5001.jpg

So far I have done: Painted the tank and sides in GM Metallic Storm Grey, new chain and new allen head bolts for the engine covers. New oil seals in the engine, New puffy grips and drag bars, new brake cable and handle, got an original rear wheel to replace the Kawasaki one that came on the bike, powder coated black (after blasting off the rattle can burnt-orange) and fabricated up some rubber dampers for the rear shocks, cleaned and re-assembled them.

Still to do: Clean and rebuild the carbs, get pod filters, clean up and attach electrical, new fuel and oil lines, figure out the seat issue, attach the lights (or find aftermarket ones) fill her full of gas and oil and attempt to start her up! I thought this would be a winter project, I think now that it's a TWO winters project. The hardest part of this is having patience.

[ConnerVT]

Well, I was wondering how you were moving along on it. She looks a *lot* different than the first pictures - and a whole lot better, to boot!

Was thinking about stopping by to see your progress, as I was up in Mallets Bay back in July. But was afraid you may have given up on the project (or hit a stone wall with it). Glad to see good progress.

[Suzukidave]

Wow !! sure looks a lot better that the first pictures you posted

[celt_rock]

Yeah, the "stone wall" I hit was the acquisition of two more bikes that I just couldn't pass on. Funny how that happens. I feel bad too because they're both Hondas. I actually found that getting them inspired me even more to finish up this... my dream bike.

If it was before July 18th I was on a 4 week trip across the USA with my family, if it was after I would have welcomed the visit and probably talked your ear off with all the questions I still have

[celt_rock]

You know Dave, I had forgotten what it looked like in the beginning until I went back and looked at the first page again. Holy cow, you're right! Just changing the fork boots and the paint did a huge amount to how this thing looks. Adding that front fender and the exhaust helps as well. Can't wait to see what it looks like with a seat on it! My kingdom for a seat, mounting bar and some bushings!

[Veebus52]

Looking good! Did you happen to make the modification to increase the transmission oil capacity while you had the case apart? I need to do that on my '72 but I want to ride it first. I'm down to just needing to get the gas tank refurbished and the season is closing in. Got side tracked by buying a 2007 V-Star 1100 and have been enjoying riding it.

[titan performance]

Looking good....I like the grey, it suits the bike IMO.

[celt_rock]

Looking good! Did you happen to make the modification to increase the transmission oil capacity while you had the case apart? I need to do that on my '72 but I want to ride it first. I'm down to just needing to get the gas tank refurbished and the season is closing in. Got side tracked by buying a 2007 V-Star 1100 and have been enjoying riding it.

Didn't have to... mine's a '75!

[celt_rock]

Just finished my last class for my masters degree and I'm back on the case!

Just finished cleaning up the carbs and filling that weird hole in the float bowl.
Good thing we just got a foot of snow! I'm running out of things I can
do to this bike whilst indoors!

[jabcb]

Just finished my last class for my masters degree and I'm back on the case!

Congrats.
What degree are you getting?

[celt_rock]

My MEd in Instrumental Music Education... really just means I can buy more motorcycles.

[titan performance]

Any luck locating a seat celt?