Suzuki 2 Strokes

Hello,

I am interested in widening the Ex port on a T500. As you may know the Ex opens at the liner and takes a 45 degree turn as it exists the cylinder a ways to the muffler downpipe. The Aluminum of cylinder, inside corner side, near muffler downpipe is where my question lies for advice.

I can tell the flow is low here since I see carbon build up. I feel I would like to take a few mm off the Al casting near muffler to improve flow and so I can widen that side of the cast liner with Burr porting tool and achieve a better flow though cylinder.

My concern is this Al may very thin near/just behind the downpipe exhaust donut and can't take too much off before breaking through. How much can I remove if that makes sense?

What have people done improve flow and especially widen the EX port and can shed somes advice (pic would be amazing).

I will do the same to intake port, but the Al material to remove is more near the cast liner and looks fairly thick.

Thanks

Sorry for double entry. Some pics would be great looking into exhaust. Here is one link but can't find original article.



https://www.google.com/search?q=Suzuki+ ... K_--rWvJCM" onclick="window.open(this.href);return false;:

Its the August 2016 issue of Classic Bike magazine. https://www.classicbike.co.uk/magazine- ... ugust-2016

A copy is available on eBay: https://www.ebay.com/itm/Classic-Bike-M ... 3806758874

Looks like Pete O'Dell of the Motorcycle Works is involved.
http://www.themotorcycleworks.co.uk/index.php/about/

there's also a chapter in the clymer manual of the suzuki twins all about tuning the 500, ports, pistons etc. unfortunately it's a bit old now, but even shows you how to build your own spannys - with 1970's dimensions
cheers, dd.

jabcb wrote:Its the August 2016 issue of Classic Bike magazine.

How did you determine it was this issue? I look at the ones on ebay, shows table of contents, but don't see T500?


I don't care if it is early 70s porting....it's an early 70s bike. I plan to do a mild version. My goal is 40 - 45 WHP. And that's a guess for maybe stock is 35 WHP good day (anyone see a dyno ... maybe another magazine had done)?


However, I sure would like to see how people took material off the Ex port before I start chipping away... Or advice. That is the goal of this post

Clicked on your link & got the press reader website. Above the Classic Workshop page is some info: “ Classic Bike (UK) 27 Jul 2016 …”

Per the Classic Bike website, the August 2016 issue is dated July 27, 2016.

Per the eBay ad, look at the cover of that issue. The gold “Classic Workshop” lists “Suzuki T500 engine strip”. Its not shown in the table of contents because its two pages & the ad only shows the first page.

jabcb,

You are correct and your last post, as written, I finally could see the black print.

The link I was trying to show was actually this one (see below). It shows two T500 cyl, one stock one ported. I almost can see into Ex but a thumbnail here in google image search. Now that link says "Vintage Motorcycles, Sundial Moto Sports" That link does not work anymore.

Did this forum pic up that Sundial site? I try to search here on "T500 porting". Many pages, but when I try to look at other pages it always says something like can do that now.


https://www.google.com/search?q=Suzuki+ ... 7KHPPJFBnM" onclick="window.open(this.href);return false;:

Sundial Moto Sports is Eric Kalamaja’s old website. Looks like he gotten interested in old Jeeps.

Look at the bottom of this page. You’ll see:
“Sundial Moto Sports forum © by Eric F. Kalamaja
Suzuki2Strokes.com”

Eric’s username on this forum is Zook-e

dollydog wrote:there's also a chapter in the clymer manual of the suzuki twins all about tuning the 500, ports, pistons etc. unfortunately it's a bit old now, but even shows you how to build your own spannys - with 1970's dimensions
cheers, dd.

I have one of those old clymers on twins. I'll try, if not late today, tomorrow, get to a scanner and post the info.

nice one dor in my infinite stupidity i never thought of that. must be having a very long grey moment atm in that article it even shows how to 'tune' the pistons with the wedges filed out of them. still think that's an interesting idea.
cheers, dd.

Jab, Dolly and Dor.

I would be real lucky if someone had a pic looking right into Ex port nice wide and clear.

Did not think the Classic Bike or Clymer has such a pic. Prove me wrong.

Maybe GT750 is similar but other post but think I saw Tz post stating T500 harder than GT750 ... Soon I will just be cutting and not to be a hypocrite take some pics (success or failure).

Jab,

Eric F. Kalamaja
Suzuki2Strokes.com”
Eric’s username on this forum is Zook-e.

Zook-e online still... I'll search posts to see if I get lucky find a pic and not hosted by Photobucket... but maybe I just need to pay photobucket... not sure what happened to the bucket.., yup i diverge.

Focus... mild T500 EX porting best practice examples please.

Some interesting pics of XR05 barrels here, which show how far porting can be taken: these have a bridged exhaust.

https://ozebook.com/suzi/2017/09/19/suzuki-tr500/" onclick="window.open(this.href);return false;

Vintageman wrote:Jab, Dolly and Dor.

I would be real lucky if someone had a pic looking right into Ex port nice wide and clear.

Did not think the Classic Bike or Clymer has such a pic. Prove me wrong........
Zook-e online still... I'll search posts to see if I get lucky find a pic and not hosted by Photobucket... but maybe I just need to pay photobucket... not sure what happened to the bucket.., yup i diverge.....

I can't prove you wrong....not what you wanted?.... but as long as I dug out the old tattered clymer, I figured I would go ahead and post what few pages there are in this 70's edition.

On the photobucket issue....try this. These or another hotlink fix worked for me in the past but not used it lately. https://forums.redflagdeals.com/google- ... x-2126190/" onclick="window.open(this.href);return false; If it did not work instantly, refresh the page and the old MIA pics should pop up.

dort500,

Thanks for trying (same with bucket tip). I am surprised I could not find any pics of someone's Ex porting work given how many times this has probably been done and how challenging it is. Maybe many before digital cameras.

It is going to be interesting to Port due to that 45 degree bend as it leaves cylinder into downpipe. If not transitioned all the way it will be in effective. Again I want to widen mostly. That article you added is just about height (bit easier to blend all the way me thinks if your only goal).

There is a lot of info here too (Port widening specs along with height)... no pic though.
http://www.ozebook.com/compendium/t500index.htm" onclick="window.open(this.href);return false;

The first page refers just a bit to the widening (1mm) No?