Suzuki 2 Strokes

Ok guys I don't really know where to start but here goes; some of you already know me and my bike from another forum dotheton (hope that's ok to mention it here). A couple of years ago I built a custom t500 with modern suspension and modern geometry with a mildly ported engine and hand made pipes. It is a 1972 chassis but I think the engine is 1975 as it has the electronic ignition. Unfortunately I never did get it running right so I am going to completely strip the engine again and totally rebuild it. Last time I didn't have the crank rebuilt because po said it had been done recently. I now believe that was not true.

Biggest problem I had was that it ran like it had an air leak, when you revved it up it the revs didn't die down right away. If you are able to watch this clip https://www.youtube.com/watch?v=5p8GTQr2kE4" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false; on youtube you will see what I mean. Eric I think the owner of this site did the porting to hopefully achieve 55hp, I am running 34mm mikuni's with custom pipes that I built to specs (using all my engine info) from I think another member on here Teaser.

I must confess that I short cut the original rebuild and now regret it. After Eric did the porting I was going to have the cylinders bored to next size over (max) and fit new pistons (i bought some on ebay for $60 brand new) but I just ended up putting new rings in it. Also I never skimmed the 0.020" off the heads that Eric suggested.

So the plan now; Strip engine completely and have the crank split and install new center seal. Buy new forged pistons (max oversize) and get cylinders bored. I need to know what clearance is needed on the bores, planning on 0.0025". Skim 0.020" from heads. Of course I installed new outer crank seals last time I rebuilt it but I will put new ones in anyway. I plan to use Bill Bune to do the crankshaft and boring unless there are any other suggestions here? I will do the heads myself.

I want to do this right this time so if anyone has suggestions for anything else I should consider doing while building the engine fire away The bike will run on Sunnoco standard leaded race gas (no more ethanol crap for me )I am building this bike to use mostly at trackdays.

Just drained the oil out before I remove the engine and it is about 50/50 oil and gas (petrol).

That's different.
I like different, it upsets the rivet counters!

I like the look.
Do you have a link to a build thread on dotheton?

Nice looking bike. I think your plan sounds about right. Good luck with it.



Lane

jabcb wrote:I like the look.
Do you have a link to a build thread on dotheton?

Here you go http://www.dotheton.com/forum/index.php ... #msg209059" onclick="window.open(this.href);return false;

Also, where is the best place in the USA to buy pistons (Wiseco) and the parts to build my crank?

Paul Miller has 3rd over Wiseco pistons listed on eBay:
http://www.ebay.com/itm/Suzuki-T500-GT5 ... 1630526305

Call Paul if you need a different size. He has a small shop so it may take a number of calls before you reach him.
He can also provide other parts like crank seals, gasket set, etc.
phone: 860 828-1771

Stock, the T500 has points & the GT500 has electronic ignition. The GT500 was sold in 76/77.
It will be useful to figure out what year motor you have. You can do that from the motor VIN.
If for example, you have an early motor with aftermarket electronic ignition, then maybe you should do the transmission mod for increased oil capacity.

Jab, thanks for the help! Mine must be a GT as it has 1400cc (which I think is the higher level)cast into the crankcase next to the oil filler. I will look at those pistons on ebay.

John.

Hi John,

I just bought a pair of T/GT500 Wossner pistons from a regular UK Wossner main dealer, there is undoubtably a similar agent in the US. Wossner do 4 oversizes from +0.50mm to +2.00mm. I paid £134 GBP + tax & delivery for the pair.

Cheers Geoff

Thanks Geoff that's a good price compared to $299 for the Wiseco's I am coming back to England next week to visit my dad so I might pick up some of those pistons while I'm there I don't see them listed on their USA website. Wossner USA distributor is only about 50 miles from me here in SoCal!

John.

Hi John,

I bought them from a company called Performance Engineering Components. They could not obtain the + 0.50mm oversize but the other sizes were available. Their Tel. No. is 01376-583030 and they are based in Kelvedon, Esses. The were not on the shelf but I assumed they then ordered from the main Euro distrubutor, they arrived within 5 days.
See link below:
http://www.steelconrods.co.uk/product_i ... cts_id=863

The part No. for the +1.00 mm pistons I bought is K8276D100-2. The D100 part of the number designates 1.00mm oversize, D150 for +1.5mm etc.

You might be able to order some and have them waiting for you when you get to the UK.

Cheers Geoff

Geoff/all,

Ok I just removed the cylinders to check my piston size and the bottom of the skirt measures 69.84mm and the top of the piston above the rings measures 69.48mm. The top of the cylinder (the unworn part) measures 69.95mm. All measured with a vernier caliper not a micrometer so should be close but not perfect. Does this mean that these are std size pistons? If so I can just go with the first oversize which I think is 70.5mm. I thought I was out to 2nd over but I must be getting confused with one of my other bikes
Wossner have some sizes available here in SoCal so hopefully what I need? Easier than bringing them back from the UK if the price is right

Thanks,
John.

Hi John,

You have std. 70.00mm pistons so you can go with 1st oversize (70.50mm).

Cheers Geoff

Thanks Geoff! I am waiting to hear if they have what I need here in California. If not I will be ordering a set from the place in Essex. My dad is in Kent so we can just take a drive over there and pick them up hopefully

Thanks,
John.

Jeezus I can get two Wossner pistons in the UK for the price of one here in the US