T500 M resto

[malky]

stunning - it makes my t500 which is the same colour and year as yours look rather tired! just finished helping a mate of mine do exactly the same resto on a kettle its taken us 18 months but boy was it worth it!- we used nick in bristol for all the bzp and powder coating etc as well excellent service cant fault him.

Mal

[subie_slider]

i got goose bumps lookin at the pics. When i get another bike ill have to completly resto mine cause of those pics.

[celt_rock]

I just purchased a T500 in about the same shape as yours and am looking to do just what you did... probably with less re-chroming as I don't have pockets that deep. Was actually torn between making it into a cafe racer or going back to complete stock. I have SO many questions for you

[celt_rock]

What did you do for wiring? Did you re-do it all yourself, buy a new wiring harness, have someone
re-furbish your old one? I think that'll be my biggest challenge, trying to figure out what wire goes
where...

[titan performance]

Superb !!

Both of my 500's started their lives looking like that.
Not now though...........

[Rustygt550]

What did you do for wiring? Did you re-do it all yourself, buy a new wiring harness, have someone
re-furbish your old one? I think that'll be my biggest challenge, trying to figure out what wire goes
where...

I removed all the old vinyl wrapping & used zip ties to hold the loom together. I drew diagrams of where each wire fitted into each connector block then removed the connectors from the connector blocks. I then cleaned the connectors with a dremmel fitted with a stainless brush. Any corroded / damaged connectors where sniped off & replaced.

The complete wiring loom was resistance tested with a multi meter.

A new PVC sleeve was also fitted. Then all the connector blocks where cleaned with an old tooth brush in hot soapy water, left to dry then re-fitted. Finally the loom was re-wrapped in new PVC loom tape.

[celt_rock]

Wow, that's meticulous! The problem I have is that the wiring was already all disconnected on this bike so there's wiring almost everywhere. I can probably
piece together what goes where but it sure would be nice to find a photo of the layout online. I look at the wiring diagram in the Suzuki manual and it makes
my head swim... maybe I should print it out and color code it myself! Thanks for the info, I think that wiring is where most of the challenge lies. I see pictures
of folks restorations with all kinds of wires sticking out of the headlight shell and I just don't have that on mine. There's a bit behind the headlight, obviously
pulled out but not as much as I've seen in other pictures. Fingers are crossed!

[ConnerVT]

I look at the wiring diagram in the Suzuki manual and it makes
my head swim... maybe I should print it out and color code it myself! Thanks for the info, I think that wiring is where most of the challenge lies.

Ask, and you shall receive.

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[celt_rock]

Wow! I LOVE this place!

[ConnerVT]

Yeah, I wouldn't be anywhere close to kicking my T500 over, if it wasn't for the info I've found here. (Re-rebuilding my carbs right now, hope to hear her run by the end of the day).

The color coded wiring diagram (as well as the modified t500wire_tympanium.jpg for updating to a solid state rectifier/regulator) saved me tens of hours of frustration when I was going through the electrical system.

There are some good folks here, and there's info you will not find anywhere else. My thanks go out to all of those who contribute.

[celt_rock]

So how North of Albany is North? I'm in North West VT and haven't found anyone else around with one of these. Any local places where you've gotten help/parts?

[jay]

WOW
Very nice !