1973 T500 cafe build

Retro, Wild, Cafe, etc. The stuff only your imagination can come up with.

Moderators: H2RICK, Suzsmokeyallan, oldjapanesebikes

User avatar
jabcb
Moto GP
Posts: 3902
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: 1973 T500 cafe build

Post by jabcb »

Installing the crank is a bit fiddly.
Imagecafe-T500-2035 by jabcb, on Flickr
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
User avatar
jabcb
Moto GP
Posts: 3902
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: 1973 T500 cafe build

Post by jabcb »

Crankcase assembled.
Imagecafe-T500-2036 by jabcb, on Flickr
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
User avatar
jabcb
Moto GP
Posts: 3902
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: 1973 T500 cafe build

Post by jabcb »

Installing the motor. The motor was light enough for me to do this by myself. Didn’t even try to pick up the GT550 motor — I just helped my mechanic friend install that motor. (I picked up & installed the bolts.)
Imagecafe-T500-2037 by jabcb, on Flickr
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
User avatar
jabcb
Moto GP
Posts: 3902
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: 1973 T500 cafe build

Post by jabcb »

Making headway.
Imagecafe-T500-2057 by jabcb, on Flickr
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
User avatar
Alan H
Moto GP
Posts: 2777
Joined: Thu Feb 16, 2012 11:50 am
Country: England
Suzuki 2-Strokes: 2 x GT550s GT750B, GS750B
Location: The Republic of South Yorkshire

Re: 1973 T500 cafe build

Post by Alan H »

And the crank on the 500 is almost 3kg heavier than the 550! Honest - my mate had just had his T500 crank done when he called a few weeks ago, and I just happen to have a freshly reconned 550 crank in the garage, so we compared them!
Think of how stupid the average person is, then realise that half of them are more stupid than that.
User avatar
jabcb
Moto GP
Posts: 3902
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: 1973 T500 cafe build

Post by jabcb »

We did the GT550 cafe motor a while ago. I was surprised at how heavy the T500 & GT500 cranks are. I don’t remember the GT550 crank being that heavy.

Am a bit curious how the weights of mostly complete bottom ends compare. With mostly complete being the assembly you have to pick up to install the motor.
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
User avatar
Alan H
Moto GP
Posts: 2777
Joined: Thu Feb 16, 2012 11:50 am
Country: England
Suzuki 2-Strokes: 2 x GT550s GT750B, GS750B
Location: The Republic of South Yorkshire

Re: 1973 T500 cafe build

Post by Alan H »

Never thought to weigh a 550 motor until it was in the frame. If I ever do another :roll: I'll try & remember!!!
Think of how stupid the average person is, then realise that half of them are more stupid than that.
User avatar
jabcb
Moto GP
Posts: 3902
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: 1973 T500 cafe build

Post by jabcb »

The motor install was actually easier than I was expecting. The T500 uses 12mm bolts. I started with an old GT550 10mm bolt that made it a lot easier to line up the motor & install the bolt. With the crank resting on a piece of wood, you don’t have to maneuver much weight to get the first bolt in.
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
User avatar
jabcb
Moto GP
Posts: 3902
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: 1973 T500 cafe build

Post by jabcb »

Those cordless torque wrenches are sweet. A great Christmas gift if you don’t have one.
The torque wrench loosened the clutch bolts & nut without doing anything to stop the rotation of the clutch!

Fingers on the 12-finger GT500 clutch have a fair amount of wear. Just took a look at the 18-finger clutch on the spare 73 T500, and wear is a lot better. Will use the 18-finger clutch.

The spare motor with the 18-finger clutch.
Imagecafe-T500-2058 by jabcb, on Flickr
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
User avatar
jabcb
Moto GP
Posts: 3902
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: 1973 T500 cafe build

Post by jabcb »

The GT500 12-finger clutch wear.
Imagecafe-T500-2059 by jabcb, on Flickr
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
User avatar
Alan H
Moto GP
Posts: 2777
Joined: Thu Feb 16, 2012 11:50 am
Country: England
Suzuki 2-Strokes: 2 x GT550s GT750B, GS750B
Location: The Republic of South Yorkshire

Re: 1973 T500 cafe build

Post by Alan H »

Mild fi,e usually sorts that. I've worn a few out! Wheelies are a barsteward on clutches.. :P .
Think of how stupid the average person is, then realise that half of them are more stupid than that.
User avatar
jabcb
Moto GP
Posts: 3902
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: 1973 T500 cafe build

Post by jabcb »

Making headway.
The EBC 18-ear T500 clutch tool is NLA at this time. So I used an impact wrench.
Imagecafe-T500-2062 by jabcb, on Flickr
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
User avatar
jabcb
Moto GP
Posts: 3902
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: 1973 T500 cafe build

Post by jabcb »

Also got this neato piston circlip install tool. A bit pricey for a single-purpose tool. Plus the tool is for a specific wrist pin diameter.
Imagecafe-T500-2061 by jabcb, on Flickr
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
User avatar
jabcb
Moto GP
Posts: 3902
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: 1973 T500 cafe build

Post by jabcb »

Found it to actually be as easy to use as this video suggests. https://www.youtube.com/watch?v=lgB2WoQbt_Q
I’m using Wiseco pistons. This video shows how easy it is with these pistons. https://www.youtube.com/watch?v=2G8FVtMzGAk&t=37s

The company website: http://www.buxtools.com/product_catalog.php
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
User avatar
Alan H
Moto GP
Posts: 2777
Joined: Thu Feb 16, 2012 11:50 am
Country: England
Suzuki 2-Strokes: 2 x GT550s GT750B, GS750B
Location: The Republic of South Yorkshire

Re: 1973 T500 cafe build

Post by Alan H »

Natty bit of kit, but getting the sods out is usually the problem unless there's a sticky out bit to grab.
Think of how stupid the average person is, then realise that half of them are more stupid than that.
Post Reply