72 T500 Rear Suspension - Baffled

[Syd]

I have a problem and I hope someone can help.

I am just about to assemble my 72 T500 rear suspension and I have the following new washers for the rear shocks from the T500 parts book (see attached drwg) - these are Item 9: # 08322-11128 = 4 x washers 22 x 12 x 2.25 and Item 10: # 09160-10001 = 6 x washers 24 x 10.5 x 2.3.

I have attached the parts drwg for the T500 rear shocks and this shows that item 10: # 09160-10001 (6 x washers), one is used on the inner and outer top suspension stud on each side of the bike and one is used each side of the inner bottom suspension stub. The trouble is, the stud diameter for the top and bottom is 12mm diameter, therefore these washers do not fit?

The other 4 x washers Item 9: # 08322-11128 are 4 x washers 22 x 12 x 2.25 which are meant to go on each of the outside of the studs. The problem is, the thread on each of the studs is 10mm OD but the ID of these washers is 12mm. They do fit over each of the 12mm OD studs. I am totally confused - is this due to a misprint in the Suzuki parts book?

Has anyone struck this before and/or has a solution?

[jabcb]

Never had the shocks off of my T500, but I think this is how it should be.

The torque spec for the shock nuts is here: http://www.ozebook.com/compendium/t500_files/torque.htm
The stepped OD of the studs + different washers allows you to torque the shock nuts up to spec without crushing the bushings.

I think its a typo as follows:
Need 6 of the 12mm ID washers & 4 of the 10mm ID washers
The 12mm ID washers go against the frame & swing arm
The 10mm ID washers are under the nuts

My T500 has only two washers at the top of each shock.
So this might be another error in the diagram or a PO might have incorrectly assembled my bike.

Compare the assembly of the bottom & top mounts on your bike.
You should be able to determine if the shock tops need 2 or 3 washers based on how much the bushings will be compressed.

[Syd]

Thanks and yes, I agree it may be a typo, however I checked the link below which seems to be in line with the parts drwg. This is a strange one indeed..

]http://www.discountbikespares.co.uk/our ... ODELS.html

DESCRIPTION: Washer, plain finish. 10.5 X 24.0 X 2.3mm. Fits rear suspension unit mounts. For specific fitment, see below. Some models require more than one washer in the top location.

T500 ALL - inner & outer suspension top, inner bottom.

[jabcb]

Take a look at the diagrams for the GT500. They are different & may be correct.

[Syd]

Thanks - yes, that would seem to make sense of all this. Could just be a typo for all these washers on the T500 parts drwg.