'76 GT500 restoration

[wvc]

Hi All,
Thought I'd start a new post to document the restoration of my 1976 Suzuki GT500 A. I purchased it a couple months ago as a non-runner sitting for about 5-10 years. I wanted to get it up and running good before tearing it down, to see what I had. Finally got it running and starting good after replacing the stator primary coils, cleaning the carbs, new battery, etc. I've been collecting a ton of new, NOS, and reprod. parts as I find them. Still trying to locate an upper brake hose, OEM style chain/axle adjusters (not the new style), and a decent front fender with the single brace. I have a small bike shop and work on bikes / sell bikes for a living, but this is my first full restoration. I really like the old Suzuki 2 strokes, and this one's the same age as me, so I thought it was the perfect one to start with. I'm hoping to have it completed in time for next years AMA Vintage Days (2011). Here's the pics from the disassembly (shops a mess, so disregard the background). Nothing like taking a good running bike, and turning it into a pile of rubble.

[rbond]

I too have a '76 GT500. The brake hoses are NLA. Have a one piece made at a autoparts house, you can probably get the copper washers there too. Do not hesitate to hit us up for info.

[wvc]

Hoping to keep the bike as original as possible. Suzuki still sells the lower brake hose, and I found a NOS middle hose. Maybe an upper hose will pop up on ebay before the bikes done. Fingers crossed.

Oh, and I need a seat. My seat pan is cracked almost in half, with lots of corrosion, and missing the metal trim. Hoping to find a used seat with a good pan, and trim pieces.

[oldjapanesebikes]

Oh, and I need a seat. My seat pan is cracked almost in half, with lots of corrosion, and missing the metal trim. Hoping to find a used seat with a good pan, and trim pieces.

If you can locate a good GT380/GT550 seat pan, you can just transfer over the GT500 mounting brackets as the pans used are almost identical. The trim is a different story.

[CJF]

My seat pan cracked almost in half as well with a lot of rust. There have been a few gt500 seats up on ebay over the past 2 years that were worth bidding on....but only a few. Seems like a lot of the GT500 seats have suffered the same problems as yours. I've also seen few front fenders come up. Mine had a non stock fender on it when i bought it...looked just like the one you have. I ended up picking up a stock one off ebay that was in fairly good shape. you shouldn't have too much trouble with that one, but you may have to rechrome if your going to do high end resto job.

[wvc]

Planning to rechrome everything, so thats no problem, if I can find one. My fender is an original GT500 fender, but has a dent on top about quarter size, and is missing the brace. Worst case I may be able to repair the dent, and use a brace from another GT series. I just found and purchased a new GT550 seat off ebay. Looks like the "new" style that Suzuki is still producing, so doesn't have the trim, but does have the "Suzuki" written on it. I may use it like oldjapanesebikes suggested, and transfer the GT500 brackets over. Or may just save it back for my GT550 if I can locate a used pan somewhere.

I'm working on getting the metal parts ready to send to the powdercoater now. Frame, swingarm, battery tray, both stands, lower triple tree, a few misc. pieces. I'm debating if I should powder coat the upper triple tree clamp, or just paint it. Seems like the original finish is just a more semi-gloss thin paint layer, than a thick gloss black powder coat would be.

[CJF]

You can have the bracket off my GT500 front fender....just pay for shipping. The bracket is in good shape, but my dender has a bunch of dings and dents. I won't be using it and it's just sitting in the basement collecting dust at this point.

[wvc]

That would be great. I sent you a PM.

[wvc]

Got all the powdercoated parts back. They turned out great. I guess I need to get my hardware sent out for replating now, so I can start bolting parts back on.

I did lose the large VIN decal on the neck when the parts were beadblasted though. And I can't find anyone that currently makes a replacement, or is willing to take the time to make one, since theres not a large GT500 market I guess.

[TLRam1]

Someone was making those decals with vin numbers, I don't have the link, maybe someone else will step up with it.

[oldjapanesebikes]

I did lose the large VIN decal on the neck when the parts were beadblasted though. And I can't find anyone that currently makes a replacement, or is willing to take the time to make one, since theres not a large GT500 market I guess.

For which country ? Tyler Tech sells a couple of different ones - may have what you need. Click here for their web site.

[wvc]

I've seen his website before. He has the smaller GT500 decal, but not the larger USA version. He has the GT750 in the large USA style though. I emailed him to ask about getting one for the gt500, but he wasn't interested in pursuing it. Same with reproduction decals.
I guess I'll probably just have to go with the smaller one from tyler tech, or may just leave the empty space, don't know yet.

[oldjapanesebikes]

I've seen his website before. He has the smaller GT500 decal, but not the larger USA version. He has the GT750 in the large USA style though. I emailed him to ask about getting one for the gt500, but he wasn't interested in pursuing it. Same with reproduction decals.
I guess I'll probably just have to go with the smaller one from tyler tech, or may just leave the empty space, don't know yet.

The label was missing from my GT500 so I wasn't sure what it looked like originally - I gather it isn't the same as the USA T500 one ?

[wvc]

Here is a picture of what the VIN decal looked like. I also emailed classic motorcycle decals in the UK, and am waiting to hear back.

[oldjapanesebikes]

That is virtually identical to the GT750 one isn't it. I gather Tyler Tech is running their stock down, so I'm not surprised they aren't interested, but really you'd think it would be such a simple thing for him to do. His GT750 ones are great - I've bought three of them, and may buy a few more.

If you do find a supplier (or want to try Tyler again) perhaps we could combine an order - his shop isn't far from my cousin's place, so perhaps an 'in person' visit would even be possible.