Magnetic Metal grains in oil on spark plugs, how bad is it?

[Pete O'Dell]

take the clutch cover off and see if there is metal in the gearbox oil, if so it will be the centre main, which was a old one when your crank was "rebuilt" I would suggest with the intermitant oil feed all the mains and likely big ends are wearing/knackered.
It might also be worth seeing if the seals are genuine suzuki or the shite pattern ones available cheaply, because not only are they shite material they dont have the castellations on the back and they can "walk" inwards and just block the oil holes

Chris applebee proclaims to have new rod kits........ no he does not! he grinds out the big end and fits larger rollers, but when you do that and just like our frog friend dino claims he uses the std rollers you buy off the shelf, they are too long so you either have too grind the ends of each roller or dress the cages or the ends wear the cages and excess heat etc.

the carbon is classic low comp and gearbox oil build up, the bores are shagged as are the pistons, what Mr Bell means is about a 45 deg chamfer no more than a mil or so wide on the piston skirt.

[Pete O'Dell]

ps, there is always the possibility you have bunged up the centre main oilway yourself with too much sealant on the cases, thats a regular built it myself failure.

[Pete O'Dell]

oh yeah, dont do what most people do and measure bore/piston clearance from bottom of skirt, they are tapered, measure point is 30/32 mill from btm of skirt ...... so measure from the top and at 90 degree's to the pin, again NOT as most people do in middle of skirt between port cut outs

lol and yes I am very busy and I also do rebores in house as well as cranks

[Nicholas]

To save all the advice on this one,just take the motor to someone "who knows" get it done properly,build Carbruetors to standard & enjoy the motorcycle,these old girls were made to be reliable & strong,never add extra oil to the fuel,creates more problems,always trust the pump!!!
Regards.
GT750Battleship.

Agreed!

I cannot avoid the jetting, don't have air box and it won't fit, my frame is braced. I'm also running custom expansions. It's not a dark art, you just gotta know what your doing or following the correct advice.

I took the carburettors for granted, ignorantly assumed it would be okay. I rushed it, Im to blame.
I'll take it on the chin and call for help on this one and next time, ill know what I'm bloody doing! I really want to ride this awesome machine!

I'll be returning to oz in the new year, so maybe you can see it.

[Nicholas]

oh yeah, dont do what most people do and measure bore/piston clearance from bottom of skirt, they are tapered, measure point is 30/32 mill from btm of skirt ...... so measure from the top and at 90 degree's to the pin, again NOT as most people do in middle of skirt between port cut outs

lol and yes I am very busy and I also do rebores in house as well as cranks

Can you fit me in mate? I'll call you tomorrow.

[Nicholas]

Chris applebee proclaims to have new rod kits........ no he does not! he grinds out the big end and fits larger rollers, but when you do that and just like our frog friend dino claims he uses the std rollers you buy off the shelf, they are too long so you either have too grind the ends of each roller or dress the cages or the ends wear the cages and excess heat etc.

I was in a bind with this one Pete, and wasn't in a good position to pack up my things. If his work is poor then I'll be paying him a visit. Right now I'd love to just set it all right and enjoy this bike for another 30+ years. Would really appreciate your help if you can fit me in.

[Pete O'Dell]

Nicks engine is currently in my workshop awaiting a full rebuild, the cause of the problems has been clearly ascertained without doubt but I am not at liberty to divulge as it may be subject too legal action, but it will be interesting when either Nick or I spill the beans

[Nicholas]

Indeed, I am not sure what to say. But don't get apples to work on your crank as they will fit seals backwards and use non-genuine seals that ultimately block the oil supply to your big ends which will destroy your engine. Thanks to Pete O'Dell my beloved GT500 is back on the road with an incredible engine, could be the best in London!

Words cannot describe how pleased I am with Pete, he is a genuine guy and is truly passionate about motorcycles. He does it for the love of bikes and helping others, I am pretty sure its not about the money for Pete.

I am quite lucky to have found him on my doorstep when I needed help, this GT500 was my first motorcycle build which went wrong when a crank I had rebuilt by another so called "Suzuki expert" went terribly wrong. The expert pretended not to know about his work, although it was returned with a distasteful and unprofessional engraving with his company details. I had no other options and so without his help my GT500 would have ended up on eBay as another failed build.

He's knowledge of the Suzuki is impressive to say the least, but what is even better is that he is always happy to answer the phone to chat at lengths about a problem without even getting paid! Thanks Pete, I am forever in your debit mate, I hope one day I can return the favour.

[Alan H]

Good to hear it turned out well and the 500 is now running well.
Shame about all the bad stuff in the middle of the story.
More power to P O'D for sorting it. Pity he's so far away, but I'll get down there one day!!