T500 520 chain conversion

[A.Holley]

It's getting time to replace the chain and sprockets on my T500.
I would like to go to a 520 in place of the original 530.
Has anyone ever done this, and are the 520 sprockets readily available.
If not, I guess I can try machining them a bit thinner to suit.
Apologies if this is a rehash of an old subject, I am a newbie here.

Andrew Holley
Australia

[Alan H]

I just wonder why you intend using a 'thinner' chain? I would imagine that it will wear and stretch faster as it won't be as strong and the pins/side plates would be thinner so it would really suit a less powerful machine (250 ish rather than 500 class?).
The 500 is quite torque-y so would tend to hammer a thinner chain, Shirley?
Interesting chain info HERE and HERE

Interesting subject, must do some more searching - we can always learn more!

Ah, THIS is what I was looking for

[Zunspec4]

Hello Andrew,

I use #520 chain on my T500 racer, other classic race bikes also commonly use #520 so no real strength issues. The front sprockets for the Suzuki RM250 are #520 and fit the T500 output shaft splines. I use a Triumph type rear hub so had some #520 rear sprockets made by B&C in the UK.

Cheers Geoff

[tricky1962]

Correct me if I'm wrong, knowledgeable folks, but I believe the standard chain for a T500 is a bit narrower than a 520.

I fitted an O-ring 520 to mine and noticed the pins fouling the plate behind the sprocket. It may have been because I switched from a standard chain to an O-ring one rather than the chain size - don't know.

Anyway, I had to fit a thin spacer behind the sprocket, moving it out by a couple of mm, to clear this plate.

Just a thought

[ConnerVT]

T500 uses standard 530 chain stock. Standard 520 chain has shorter pins, and I believe the same length between pins, as the roller diameter is the same for both.

http://www.didchain.com/chainSpecs.html

[A.Holley]

Thanks for the info, gives me somewhere to start.
I have always thought that a 530 chain is overkill on a 500, plus I m lays looking for ways to reduce unsprung weight etc.

Andrew

[Jimroid]

DR200 rear sprocket (520 chain)will fit T/GT. Some (JT) come with both 8mm holes and 10mm. Other brands may only come with the 8mm holes rectified with 10 minutes of drilling out to the 10mm.

[A.Holley]

That's useful to know, will check into them and see what sizes are available.
Anyone know what front sprocket will suit?

Andrew

[Jimroid]

PE250 and RM 's from the 70's & 80's , Yamaha XT 250 to name just a few. So much useful info on the JT sprockets online .http://www.jtsprockets.com/catalogue/sprocket/JTF431" onclick="window.open(this.href);return false;

[diamondj]

Way back in a previous incarnation of this board user Jughead posted a cross reference for stock Suzuki 520 sprockets that would fit the front as well as where to get rear sprockets milled down. His post is buried somewhere the the mass of "archive" posts you get to if you dig deep enough on this board. Happily I have regurgitated his post often enough that I can usually find a previous reposting. Since you are in Australia your experience may vary and the prices I list are woefully out of date:

To Adapt the T500 Countershaft Sprocket to a 520 Chain which is Narrower than the Stock 530 Chain you will need to Find a Sprocket from one of the Following Models.
Part # = 27511-41120
Part Description = SPROCKET,ENGINE
Model Count = 20
PE250B 1977
PE250C 1978
PE250N 1979
PE250T 1980
PE250X 1981
PE400T 1980
PE400X 1981
RM250A 1976
RM250B 1977
RM250C 1978
RM250C2 1978
RM250-N 1979
RM250-T 1980
RM370A 1976
RM370B 1977
RM400C 1978
RM400N 1979
RM400T 1980
RS250T 1980
RS250X 1981

To Adapt the rear to a 520 Chain you can contact Sprocket Specialist at http://www.sprocketspecialists.com and have a stock 530 Rear Sprocket Machined Down for $25.According to Zook-e the $25 Machine Bill covers 1 or More Sprockets to be Machined.
The Part Number for the Front Sprocket is 516 and Comes in sizes 11-16 Tooth and Costs $13.00
The Part Number for the Rear Sprocket is 159 and Comes in Sizes 30-71 Teeth Price Varies on What Size you Order.Cheapest Being $53 and the Most Expensive will be $99
The 159 Sprocket Covers the Following Suzuki Models According to the SS Website.
GS400 77-78
GS425 79
GS 450 80-83, 85-88
GS 550 B, C, N, ET, LZ SPOKE 77-82
GT 380 73-77
GT 500 76-77
GT 550 71-77
T500 68-75

Another Helpful Website with an Online Catalog is http://www.jtsprockets.com

I found the Sprocket Specialist rears were about $55 to $59 per when I ordered them. The fronts I found on Ebay for around $10 per sprocket. And I was able to find 13, 14, and 15 tooth fronts.

As for a chain, since this set-up is narrower you can fit a 520 "O" ring or "X" ring chain with some clearance to spare. I've found the RK GB520MXZ3 (non o-ring) to work well and have excellent tensile strength. Best of all they turn up on Ebay from time to time for around $50 a chain. I ran one on the GT500 based race bike I bought from Mowgli with no problems so it should survive street duty just fine....