Suzuki Twin first-timer

[Ofeargall]

I recently acquired a 76 GT500 with a title and complete manual for $50. My son and I did a top-end on his TS185 and I've done a complete rebuild on a completely seized TC90 as well, but this is my first two-stroke twin.

The bike, which we've affectionately named "Grant" (the US president on the fifty-dollar bill), has a seized engine, worn out tires, tired forks and rusted exhaust guts. Sounds bad, I know... We're not attempting to make a show bike. We don't "thrash" our bikes, but we don't baby them either so a show bike has no place in our garage.

I'm wondering about the exhaust. Can I replace the inner pipe with a straight pipe that's drilled and re-pack the fiberglass? The chrome outer pipes are decent enough and we can live with them. We're not going to race the bike so I'm not interested in bulbous expansion chambers and mosquito sound effects. Besides, I like the long, low straight look as well as the (reportedly) smooth power curve.

Thanks in advance.

[Coyote]

Time to innovate. What you are calling the inner pipe is in fact a baffle. Those are still available from Suzuki, but cost is around $260 for the pair. Hardly worth that investment on a $50 bike. You can gut the pipes and run without them, but the sound isn't all that nifty and it will hurt the performance some. Might require some jetting changes as well.
As you know by now, baffles are an intricate part of how a 2-stroke runs. I would keep scanning eBay for a used one. Get it and use it for a pattern to fabricate new ones.

[Ofeargall]

Thanks Coyote, good idea. I'll see what I can find. I didn't know you could get the parts separately, that's good news. As I mentioned, I'd like to keep the power curve/jetting/mileage as close to original since it sounds like Suzuki got it right (from what I've read).

[rbond]

There are at least two companies overseas that make reproduction mufflers. It started with $50, but you can quickly run up a bill just on parts.Decide if you want to commit to fixing up this bike, I have a '76 GT500. For me it is worth it, the sound feel, etc. is like no other. Plus the knowledge that you (hopefully) fixed everything RIGHT yourself, all that gives you an 'intimate' feel for the bike. You can feel when everything is going right and when something is a little off. It is not just having a 2 stoke twin, it is almost a marriage of man and machine..... Yes the blasted thing vibrates at higher speeds, get over it, wear thick gloves. I have found the people on this site to be very helpful in advice and a few parts. A member in France makes repro fork boots, I have made repro CDI boxes, check the posts on that here too. Once fixed up, great rides are ahead! You won't get your money back if you sell it, it is cheaper to keep it...

[Coyote]

You won't get your money back if you sell it, it is cheaper to keep it...

'
Amen

[Ofeargall]

Unless you're Jay Leno and can buy obscure bikes in pristine condition, motorcycles are likely the worst investment, besides farming, that a human can make. Whether new or old, most motorcycles just don't hold value. With that in mind I've purchased mainly older bikes because we can work on them and they have a mechanical and aesthetic quality that is hard to find in newer machines.

There may come a day when I buy a mile munching car with two wheels, but for now I'm happy loosing my money to the mechanical equivalent of gambling at Black Jack. In both cases you'll eventually end up with something running in your favor.

[Zunspec4]

My take on the sentiments expressed by Ofeargall are in parallel. Unless you luck onto one of the rare highly desirable machines (board track Harleys, Brough Superiors, Vincents etc.) the worth of your immaculate restoration is likely to be about half of what you have invested. What you will get out of it is a great deal of fun, exasperation when things awry, jubilation when you triumph, the pleasure of riding a machine that YOU have brought back to the road. You will probably have a machine that does not depreciate but will appreciate in value. The point when it is worth what you put into it may be a few years down the timeline unfortunately

Cheers Geoff

[Ofeargall]

Good word Geoff.

The pistons on "Grant" are soundly seized into the jugs. We're building a puller plate and starting that dance soon.

This is a chance for me to work on a bike with my son. We're going "halvsies" on all the parts and machining to get the bike on the road again. If he likes it, he'll buy me out. If not, I'll buy him out. We did the same with his TS185 which you can read about here: http://23moto.com/georgia-the-1972-ts18 ... d-the-day/" onclick="window.open(this.href);return false;

[Zunspec4]

It sounds like the two of you make a good team, Ofeargall I'll keep an eye on your posts to see how the project comes along.

Cheers Geoff