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PostPosted: Wed Apr 11, 2018 5:26 am 
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To the on ramp

Joined: Fri Jun 19, 2015 5:14 am
Posts: 255
Country: USA
Bikes owned: T500
geck0 wrote:
https://www.ebay.com/itm/Suzuki-T500-Show-quality-Tank-Side-Cover-set-1972-T500J/202272257002?hash=item2f185db3ea:g:CmUAAOSw~qxauV3S&vxp=mtr

Not sure what your plan is.. Your bike does look nice and these Paul Miller tanks are top quality.



.....but then you would have to deal with Paul Miller.


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PostPosted: Wed Apr 11, 2018 9:18 am 
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On the street
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Joined: Tue Mar 27, 2018 12:11 pm
Posts: 16
Location: Vancouver Island, BC
Country: Canada
Bikes owned: 197? GT 250, 2000 GSXR 600, 1972 T500J
This should work..

https://www.youtube.com/watch?v=aT74wZRyU6A" onclick="window.open(this.href);return false;


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PostPosted: Wed Apr 11, 2018 10:11 am 
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Novice racer
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Joined: Wed Jan 18, 2012 8:01 pm
Posts: 930
Location: North of Albany, NY
Country: USA
Bikes owned: T500R (now), T500M (30 yrs ago)
Torch. Gas tank. What could go wrong?


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PostPosted: Wed Apr 11, 2018 11:09 am 
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On the main road
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Joined: Mon Jun 12, 2017 12:01 pm
Posts: 167
Location: Galveston County, Tx.
Country: USA
Bikes owned: '75 T500M since '93 Ridden it over 100,000 mi
Fire....oil canning....distortion...Oohhh My. :shock:

That fuel tank you have, from what we have seen of the outside, is in very good shape. That makes it rare and valuable and entitled to a little extra labor.

I suggest at least trying the chemical route .....it's just a polyester base filler....plastic. If it gets down to where you can't completely clean out the threads (and how many people have a metric thread chaser that small?) pay a gunsmith a few bucks to do it. If he happens to own a motorcycle, he would probably do it for free. :wink:

Your call of course. Get these little details out of the way and you can move on to the 'Main Event'. :arrow:

Good Luck on whatever you decide.

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PostPosted: Thu Apr 12, 2018 11:50 am 
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Around the block
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Joined: Fri Apr 15, 2011 4:50 pm
Posts: 96
Location: North Country - New York
Country: USA
Bikes owned: T500's
I agree that you should try to open the badge holes Try heating a pick with a torch and work the holes Heat should break the bond Im not sure if the thread is #3 or #4 mm

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T500R (Stock)
T500J (Next Stock Project)
T500? (Cafe project 34.6%)
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PostPosted: Fri Apr 13, 2018 2:47 pm 
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On the main road
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Joined: Mon Jun 12, 2017 12:01 pm
Posts: 167
Location: Galveston County, Tx.
Country: USA
Bikes owned: '75 T500M since '93 Ridden it over 100,000 mi
When the time comes that you want install new trim to the fuel tank, here is where I bought mine. I bought 8 feet total. The additional four feet was in case I screwed something up. :wink:

:arrow: https://www.ebay.com/itm/CCG-UNIVERSAL- ... rI&vxp=mtr" onclick="window.open(this.href);return false;"

Image Image
Image Here temporarily installed on my unfinished and not clearcoated yet tank. Image

I did have to cut just a bit of a notch in the back of the trim to better clear the front hold down tab on both sides to butt it tight to the tank. If you decide to get it, just dry fit first before you start cutting for length....you'll see what I mean around the front tabs.

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PostPosted: Fri Apr 13, 2018 5:50 pm 
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On the street
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Joined: Tue Mar 27, 2018 12:11 pm
Posts: 16
Location: Vancouver Island, BC
Country: Canada
Bikes owned: 197? GT 250, 2000 GSXR 600, 1972 T500J
Thanks for that info. As you can imagine, I am a little ways away yet. At the moment I am looking for a local source for the heaviest duty paint-stripper I can find. Then I will start the process and see how it goes.

In the meantime I am doing a bit more work on getting the engine stripped.

Cheers.


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PostPosted: Thu May 10, 2018 10:13 am 
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On the street
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Joined: Tue Mar 27, 2018 12:11 pm
Posts: 16
Location: Vancouver Island, BC
Country: Canada
Bikes owned: 197? GT 250, 2000 GSXR 600, 1972 T500J
Heads, pistons and bores look to be in good shape.


Attachments:
heads.jpg
heads.jpg [ 64.79 KiB | Viewed 560 times ]
pistons.jpg
pistons.jpg [ 105.32 KiB | Viewed 560 times ]
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PostPosted: Thu May 10, 2018 2:42 pm 
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Road race school

Joined: Wed Jul 10, 2013 12:04 pm
Posts: 799
Country: England, UK
Bikes owned: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S
Looks good. Did you put the cooling holes in the heads?
My head has holes like that too.
Just wondering what the countersunk screw is supposed to be doing. Is that in the cci port?


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PostPosted: Thu May 10, 2018 4:41 pm 
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On the street
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Joined: Tue Mar 27, 2018 12:11 pm
Posts: 16
Location: Vancouver Island, BC
Country: Canada
Bikes owned: 197? GT 250, 2000 GSXR 600, 1972 T500J
No, that's the way the heads came.

The screws and bolts I put in to keep junk out of the ports.

Anyone have a trick for rotating the piston circlips so I have enough to pry or get hold of with pliers? I got one piston off no problem, the circlip was easy to access in the gap at the top of the piston. I am having a hard time getting purchase on the circlip on the piston on the other side. Unlike the first side, not much,if any of the circlip is showing at the gap in the piston. I have tried pushing it round further but no luck so far. Just try harder? :oops:


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PostPosted: Thu May 10, 2018 6:25 pm 
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On the main road
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Joined: Mon Oct 24, 2016 12:35 pm
Posts: 114
Location: Macon, GA
Country: USA
Bikes owned: 76 GT750, 72 H2 750, 84 RZ350, 67 YR1, 82 MB5
A hook and pick set works well for me removing piston circlip. I use a small flathead screwdriver to seat them upon installation after getting one side started with my finger.


Attachments:
IMG_6262.JPG
IMG_6262.JPG [ 35.37 KiB | Viewed 528 times ]

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PostPosted: Thu May 10, 2018 7:19 pm 
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On the street
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Joined: Tue Mar 27, 2018 12:11 pm
Posts: 16
Location: Vancouver Island, BC
Country: Canada
Bikes owned: 197? GT 250, 2000 GSXR 600, 1972 T500J
OK, thanks for that. I have some picks that are a bit on the flimsy side. I will try grinding the tip down on one, so it is a bit sturdier, hopefully that will get a result. Cheers.


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PostPosted: Sat May 12, 2018 2:57 pm 
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Road race school

Joined: Wed Jul 10, 2013 12:04 pm
Posts: 799
Country: England, UK
Bikes owned: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S
I just use a small screwdriver


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PostPosted: Sun May 13, 2018 3:06 pm 
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On the street
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Joined: Tue Mar 27, 2018 12:11 pm
Posts: 16
Location: Vancouver Island, BC
Country: Canada
Bikes owned: 197? GT 250, 2000 GSXR 600, 1972 T500J
Result!


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PostPosted: Sun May 13, 2018 3:34 pm 
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On the main road
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Joined: Mon Jun 12, 2017 12:01 pm
Posts: 167
Location: Galveston County, Tx.
Country: USA
Bikes owned: '75 T500M since '93 Ridden it over 100,000 mi
1T500closertodivorce wrote:
Result!
:) 'Man of few words usually has wife that has many words'. :D

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