T500 Engine Tear Down Procedure?

[celt_rock]

Okay, so I've got the jugs and pistons off the engine and at first I was thinking of opening it up in order to clean/flush out the thing. Now I'm getting nervous as I've never done anything like this before and I'm thinking... "why fix it if it ain't broke". Only issue is, I don't know if it "ain't broke".

So the question is, does anyone have a step by step explanation of how you break apart a T500 engine (without doing too much damage) so I can check the gears and flush out the crud? Do I need to take the clutch apart? That seems really complicated and I'm nervous about putting it back correctly. I've done a search of this forum to see if anyone has posted this before... I hate asking questions that have been answered ad nauseam... but haven't been able to find anything other than a really nice picture of the inside of a T500 Engine.

At the same time, if you think this is something that I should NOT undertake, maybe someone has a proven way of flushing the engine with it still in tact... chemicals that can be run through?

Thanks a lot guys, this has been a blast so far. My frame goes to the powder-coater tomorrow and then I can start basic re-assembly... my favorite part!

[tz375]

Manuals do a pretty good job of covering the basics and to be honest, they are pretty simple to strip and rebuild. if/when you have an issue, just ask as you go along and you'll work out the things that you don't know.

It doesn't take a whole lot of special tools or years of Suzuki secret handshakes to learn the magic code. Armed with a manual, good tools and a patient logical approach I suspect that you will surprise yourself. Don't be in a rush and get copies of the parts lists to see how parts fit together. Take lots of photos and notes and put parts into bags with labels. Or use lots of cheap baking trays to put parts into.

[titan performance]

Plus one to everything TZ has said. They are very simple engines. The clutch is very simple too, but you will need to remove it to split the cases. There is a hidden plate behind the clutch that joins both halves. There's no need to puzzle over anything, just post the issue here, and the answer will come...

[rbond]

Google for 'Ozebook' in Australia for manuals too. Between both forums you will have more than enough help. These are very basic, simple bikes to work on. That is what made Suzuki, simple, reliable two strokes. Kinda the Timex watches of motorcycles, 'just keep going on' (ticking?). If you are going to learn motorcycle mechanics, a two stroke is the best to start with, if you do move to four strokes, stay with Suzuki GS series, same reliability. Just like the two strokes, they had a few inherent problems, which have been dealt with too. GSresources. Some parts interchange between the T/GT line and the GS, so think parts upgrade/ alternative source. Welcome to the club!!

[celt_rock]

Thanks guys. Stip-it it is. I'm going into the studio to finish up the final mixes of my band's live album and then I plan to hit it full force. The frame is at the powder coater right now and he said it would take a couple of weeks. It's -10 degrees here now so even
may basement is too cold to work. Hoping for a snap of this cold by the weekend. I think the clutch has been the most intimidating thing. All those parts and I'm not confident about being able to get it back together again the right way. I guess there's nothing to lose (except the original engine to my bike ).

Wish me luck!

[ConnerVT]

Disassembling the clutch isn't very difficult. Once you begin to take it apart, you'll easily understand that your fears were unnecessary.

I do have one recommendation -- pneumatic impact wrench.

You'll need to remove 3 (22mm? if I remember) nuts which hold the front sprocket, the clutch basket, and the primary drive gear. Especially since your engine is off the frame, you will have a bear of a time getting all three off. There are tricks for locking things into place, but I spent several days (and one broken clutch basket) fighting those three nuts. Borrowed my brother-in-law's compressor and impact gun, and had the nut off the clutch basket in a 2 second pull of the trigger.

[titan performance]

Those nuts can be tough, and the engine being out of the frame makes it a bit harder, but chock the dogs with a bit of rag to stop things turning, and if you don't own a breaker bar, or air gun, get a mate to steady the motor, and slip a tube over your ratchet handle.....

[ConnerVT]

I did say there were other ways to do it.

You can have a root canal without anesthesia, too. I just don't recommend it.

In this case, my opinion is that the power tool is the right tool for the job.

[redline]

A battery powered impact driver does the job nicely too.

[diamondj]

Don't forget you can download the factory manual here:

http://file.walagata.com/w/sundialmotos ... kiT500.pdf

and it covers tear down pretty well... Post up where you get stuck and we'll help.

Jim

[celt_rock]

Thanks everyone, I got the clutch basket off, it actually came off scarily easily. Just used the cloth jamming technique and a quick rap on a wrench and it came loose. The washer only had one ear folded over as opposed to two, makes me wonder if this was off before. Waiting for some time so that I get all the other little bits off and then attempt case separation.

Thanks for the link Jim, I can't seem to get it to work though. I'll do a search for what you're talking about and see if I can come up with it on my own. Powder coater called and the frame is already done... two weeks early! Guess I gotta kick it into high gear!

[diamondj]

Hmm,

Sorry - I messed up the cut and paste. Let me try that again:

http://file.walagata.com/w/sundialmotos ... kiT500.pdf

If that doesn't work, the link is in the link to cool sites section:

viewtopic.php?f=19&t=151

Jim