T500 frame - not quite symmetrical

[Fritz500]

Finally removed all the bits from my T500J frame to get it ready for grit blasting and painting.

The rear end looked a bit wonky. Also if you look at the photo you can see the tube that connects head stock to the frame is offset (by 7mm).

I ran some string lines to see the extent of the problem. The left rear section of frame that extends to the rear mudguard support appears to be bent in by around 12mm. I'm going to see if I can find a local guy who can straighten it.

I don't know whether this is accident damage - there were indications of a crash at some stage. The gear lever shaft end was bent and the top triple clamp looks like it has taken a whack as the threads for the left indicator are shot.

I didn't imagine Japanese built quality was this bad back in the 70's...unless they sub contracted it out to trained monkeys who weren't good with a tape measure. The welds all look crap too, strong I suppose but crap looking.

Oh the joys of restoration.

[argo1974]

This is not an accident damage but normal to T500 frames. I already had to straighten two 73" frames with similar issues.

[Fritz500]

How was yours straightened? A bit of heat and a bit of brute force?

I looked at my other 500 and it was no where near as bad.

[tz375]

Are you 110% sure that the frame is bent and not just that one tube welded off center? There is no way that a crash can move a welded tube sideways if you follow me. Time to get the frame into a jig and see what's straight and what's just crappy assembly welding that's inelegant but has few consequences.

[titan performance]

We put a 71 together recently, and hadn't noticed any problems until trying to bolt the headers on. We favour converting the M8 bolts to studs, but the header clamp on the left cylinder wouldn't pass between the stud and the frame tube, and the only way to mount it was to hold the clamp in place, and screw the stud in, whereas the other side was clearly accessible, with plenty of space to insert the stud, and then put on the clamp afterwards. The difference in mm was a lot ! We couldn't figure it out, but it gave the impression that the motor sits pissed in the frame. As TZ says, we concluded it was clumsy assembly, as there seemed no way an accident could have had this result.

[Fritz500]

Are you 110% sure that the frame is bent and not just that one tube welded off center? There is no way that a crash can move a welded tube sideways if you follow me. Time to get the frame into a jig and see what's straight and what's just crappy assembly welding that's inelegant but has few consequences.

No, me thinks two separate issues. The front tube was welded off centre when Mr Yamamoto came back from his lunch break after sipping too much sake. I can live with the front bit.

The rear is what bugs me, it is either poorly assembled or re-aligned by a left side fall or both.


Cheers

[Suzukidave]

If i remember correctly there was a story on the Kawasaki list of a bottle being found welded inside a Kawa triple gas tank

[Fritz500]

I thought I'd do a Google search for "things found in..."

Google suggested "things found in peoples bums"

I backed away slowly from the PC and found something useful to do.

[argo1974]

Head stocks were pretty straight on my frames but both of them had the rear section bars bent to the left.
I got it straightened with adding heat (until red) and bending with a tube slid onto rear section bar.

[Fritz500]

Head stocks were pretty straight on my frames but both of them had the rear section bars bent to the left.
I got it straightened with adding heat (until red) and bending with a tube slid onto rear section bar.

What did you use to heat it? I can get hold of a propane torch but wasn't sure it would get hot enough.

[argo1974]

I went with acetylene torch ... but propane torch of bigger size will also work.

[Suzsmokeyallan]

Suzuki have had issues with frame spars and other brackets and small parts getting welded in crooked for years, even Bandit frames of recent had this problem too.
On my 69 T500 frame I had to 'tap' in the two plates by the swingarm pivots as they were splayed out a bit for some reason, which I contribute to the heat/cooling from initial welding.
On my GTs a lot of the cross braces are off by a few MMs which means its enough to notice if the frame is bare.
On my GSX1100 frame one top shock mounting post was bent in the welded gusset which I repaired. Also the centre stand left "shoe" also had to be cut off and repositioned as it was put on very crooked which made the bike slip forwards on that side very often when lifting it onto the stand.
That top centre brace was installed crooked on your frame and as long as the head tube is not compromised it can stay as it is OR you can cut it and reposition it.
Gently heating non critical frame parts and getting them back into the correct position is easily done. Sometimes a stout piece of hardwood and a heavy hammer can realign minor tweaks too if you are proficient with such procedures.

[Fritz500]

Suzsmokeyallan,
I went to a bike engineering place to get a quote. "To bend or not to bend, that is the question"

The guy was well set up to do the work but really only wanted to do a complete check of the whole thing and said it would take 8 -12 hours. Given the labour costs here, his price scared me. I'm sure his work would be top class but I have a budget (whatever that means).

I'm trying to buy a propane torch off FeeBay and as suggested a few large hunks of wood and a large steel headed inertial energy impact device will be used.

Cheers

Geoff

[Alan H]

I'm trying to buy a propane torch off FeeBay and as suggested a few large hunks of wood and a large steel headed inertial energy impact device will be used.
Cheers
Geoff

Just 'borrow' a plumber for an hour.
All the 'real' (read 'older') ones will have a BFO gas torch that will do the job (as well as little piddly ones for small pipework in cupboards!)

[Fritz500]

"Borrow a plumber". Good idea. I was going to get some plumbing down around my place...might have the bike ready a bit of "heat & hit"

Thanks