Lyster Suzuki T500 build

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titan performance
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Re: Lyster Suzuki T500 build

Post by titan performance »

That's lovely work.....
We bought an Edwards roller from a local engineering shop that was closing. I believe it to be well over 100 years old. I've rolled a million cones on it, all 0.9mm. Problem is, I taught myself, and my work always finishes on the top roller, but it's the bottom roller that opens to release the work....done too many to change now.
I think you did right making your rollers 1.5"......ours are 2", and require some fettling before they go to the welder.
Good luck with your machine, I'd be interested to hear how you get on....it's not easy at first.
Keeping old 2 strokes alive !
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smokin_blue
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Re: Lyster Suzuki T500 build

Post by smokin_blue »

Hey guys it has been a while since I have posted. Sorry this summer got busy. Now I am starting to get back to it a bit (although it is competing with building a custom for my wife as well). The question I have for you guys is what is the general state of the stock gearing on the T500? This will be a road going hot rod rather than a track bike. I am planning to switch to 520 chain. With that I can stay with the stock gearing of a 33 rear or I could easily move to a 35 tooth as an off the shelf option as well. Would you advise for going up two on the rear for more pep or am I better off staying with stock gearing?
'07 Suzuki SV650
'90 GSX-R1100 streetfighter
LS650 powered custom framed café
'72 T500 with a Lyster frame
'69 T500-parts/project?
'83 GR650-project

Past bikes
'06 Triumph Sprint ST
'86 GSX-R750
'74 GT250/T350 custom
'79 GS750
'74 TS250
'81 TS100
Zunspec4
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Re: Lyster Suzuki T500 build

Post by Zunspec4 »

Hi smokin_blue,

The stock g/box has a bit of a gap between 1st - 2nd but is fine from there. I think you will find the overall gearing will need to be lowered, stock ratios will be too high. My race g/boxes both have a higher 1st gear and my Primaries are different to stock as well but as a reference I run 15T front and 38T-42T rear. If you are looking for 520 front sprockets those from an RM250 will fit.

Cheers Geoff
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smokin_blue
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Re: Lyster Suzuki T500 build

Post by smokin_blue »

Thanks! I went ahead and ordered the 15 front RM sprocket earlier in the week. Then I decided to pull the trigger on an off the shelf 35T rear that was priced very well. it will be a good starting point.

I was starting the design for the swing arm (my frame was missing the Lyster swing arm) but I have decided to pause and move to getting my rear hub done so I know exactly what I am putting between the arms and how much width I need for sure. As mentioned earlier I want to run rear disc (since Lyster as a MC disk pioneer) so I have a GS750 rear hub that I plan to modify to accept the rear sprocket carrier and cush rubbers from the T500. At that point I will also put the GS style bushing in so get away from the way the T500 mounts the sprocket carrier to the SA with it's own large nut outside the axle.
'07 Suzuki SV650
'90 GSX-R1100 streetfighter
LS650 powered custom framed café
'72 T500 with a Lyster frame
'69 T500-parts/project?
'83 GR650-project

Past bikes
'06 Triumph Sprint ST
'86 GSX-R750
'74 GT250/T350 custom
'79 GS750
'74 TS250
'81 TS100
Zunspec4
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Joined: Tue Dec 16, 2008 11:37 am
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Re: Lyster Suzuki T500 build

Post by Zunspec4 »

smokin_blue wrote:Thanks! I went ahead and ordered the 15 front RM sprocket earlier in the week. Then I decided to pull the trigger on an off the shelf 35T rear that was priced very well. it will be a good starting point.

I was starting the design for the swing arm (my frame was missing the Lyster swing arm) but I have decided to pause and move to getting my rear hub done so I know exactly what I am putting between the arms and how much width I need for sure. As mentioned earlier I want to run rear disc (since Lyster as a MC disk pioneer) so I have a GS750 rear hub that I plan to modify to accept the rear sprocket carrier and cush rubbers from the T500. At that point I will also put the GS style bushing in so get away from the way the T500 mounts the sprocket carrier to the SA with it's own large nut outside the axle.
Hi smokin,

The RM f/sprockets are also available in 13T and 14T so you have scope to easily lower the gearing.

I am using a copy of the Triumph T140/T160 rear hub produced by Minnovation Racing in my Seeley. You can get these with a cush hub but I did not fit one. The cush drive in the clutch basket being sufficient for racing. The r/sprockets I sourced from B&C Express, they used their existing Triumph pattern but cut from a #520 blank.

Minnovation rear hub
Image Image

B&C Sprockets
Image

If you are yet to design and make your Lyster s/arm and want to fit a wider rear tyre you will probably need to space out the front sprocket. When I changed tyres from a 110/80 to the Avon 130 Cantilever I had to space the front sprocket by 9mm. With this off-set you cannot simply place a spacer behind the sprocket as the nut will not fully engage on the shaft. I had custom 9mm off-set sprockets made by Talon Sprockets for this.

Image

Cheers Geoff
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Re: Lyster Suzuki T500 build

Post by smokin_blue »

Geoff,
It seems any pictures you post of your bike are just absolute eye candy! I love that build you have. Sorry for the delay in response, I took a bit of a holiday from work and we left the snowy north and went to Florida to visit my son. It has provided some down time to work on bike designs so that is a bonus!

My rear hub has been a challenge in my build. It has a lot of constraints but I think I will be able to make this work and still look good. I wanted the rear disc as mentioned earlier in my posts, but I also wanted to cush drive since I will be driving it on the street. With the limited miles this bike will probably see I could have probably gotten by without but I don't want to risk the transmission. The next limiting factor is the small rear sprocket diameter. many more modern hubs have a larger mounting diameter so those are out, and I already have the 36 hole rear rim I plan to use so there again narrows the field.

Ultimately my plan one I get back home on the milling machine is to take a '79 GS750 rear hub and modify it to work. I need to take out 9mm from the current stack up. I plan to narrow the hub slightly to accept the T500 sprocket carrier. Then I will have to take the remaining mm off the outer face of the sprocket carrier which appears to have plenty of material for what I have to take off. That should put the left side in alignment. From there I need to mount a brake rotor and caliper on the right side. I want a small rear rotor something in the 240mm range. My window currently is 220-250mm but I don't know for sure what I plan to use. Lyster ran his brakes above the SA and in front of the rear shock. That arrangement won't work for my swing arm design so I am planning currently to hang it below the SA. Depending on what I go for with a disc I may have to make a disc carrier which is not a major deal, I just need to get home to measure out my stack up once my rear caliper arrives.

My last constraint is I don't have any luxury in the width department. The lyster frame was a very narrow frame. I it is 7" between the sides. I am splitting hairs on centering the engine, going to a 520 o-ring chain and still having minimal appropriate frame clearance. This does not leave me with any ability to push the chain outboard as you did. This likewise will limit my tire choices to about a 110 possibly a 120 max width.

The frame was originally designed by Colin to house a CB450 so it was a very narrow. They also would take them and with additional engine mount plates drop in a 650 triumph engine but again it allowed for a narrow design.

Once I have the rear hub sorted then I can finish the SA design. That likewise can't get very wide due to the narrow frame also then affects the top shock mounts. Those set the shocks fairly narrow stance as well. I am planning a classic Ducati SS style SA with round tube all the way (no tangs) and alloy axle carriers/adjuster plates. Athough the style is not what Lyster built it should look good with the frame. Personally I don't care for the style SA that he went with, not sure how exactly he fabbed them as it appears to be round or oval on the outside surface and flat on the inside and then running the adjuster plates on the SA pivot rather than at the axle.
Last edited by smokin_blue on Sat Dec 21, 2019 9:14 am, edited 1 time in total.
'07 Suzuki SV650
'90 GSX-R1100 streetfighter
LS650 powered custom framed café
'72 T500 with a Lyster frame
'69 T500-parts/project?
'83 GR650-project

Past bikes
'06 Triumph Sprint ST
'86 GSX-R750
'74 GT250/T350 custom
'79 GS750
'74 TS250
'81 TS100
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smokin_blue
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Re: Lyster Suzuki T500 build

Post by smokin_blue »

As another update I did get my front discs turned down this past fall. They fit well but boy Honda uses some tough stainless in those things. The shavings would not form chips but were long stringy gold colored (from the heat of the cut) razor sharp wire. The triple is welded up and coming out nice. And the forks look like they should work ok. I just have to settle how much if any I am going to shorten the fork and travel. I was able to put late model slab side Gixxer bearings in my GT front hub to accept the 17mm axle of the SV650 forks. That is all good. I just have one issue with a small tab on the calipers running very close to the button heads on floating rivets of the disc carriers. I think I can trim the tab just enough to allow clearance. If not it will back up the entire front end design back a few steps.
'07 Suzuki SV650
'90 GSX-R1100 streetfighter
LS650 powered custom framed café
'72 T500 with a Lyster frame
'69 T500-parts/project?
'83 GR650-project

Past bikes
'06 Triumph Sprint ST
'86 GSX-R750
'74 GT250/T350 custom
'79 GS750
'74 TS250
'81 TS100
Zunspec4
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Re: Lyster Suzuki T500 build

Post by Zunspec4 »

Hi smokin :D

I'll have to digest your last two posts lol, but the squeeze to get the front disc in, not hitting anything, keeping it in the centre of the caliper channel etc. is something I'm STILL trying to master on my Seeley. Highly bling lower fork sliders have been attacked with files/milling machines. AP callipers have suffered the same fate. Spacers on the disc mounting and shims on calliper and carrier are legion lol :D

I've only been at it 6 years, I'll get it right eventually.

Cheers and the best seasons greetings :up:

Geoff
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Re: Lyster Suzuki T500 build

Post by smokin_blue »

Geoff,
I sent you a PM or we could turn this entire thread into a custom brake discussion! :lol: :lol:
'07 Suzuki SV650
'90 GSX-R1100 streetfighter
LS650 powered custom framed café
'72 T500 with a Lyster frame
'69 T500-parts/project?
'83 GR650-project

Past bikes
'06 Triumph Sprint ST
'86 GSX-R750
'74 GT250/T350 custom
'79 GS750
'74 TS250
'81 TS100
Zunspec4
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Joined: Tue Dec 16, 2008 11:37 am
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Suzuki 2-Strokes: T500R, SV1000S, TS125, Seeley T500
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Re: Lyster Suzuki T500 build

Post by Zunspec4 »

Hi Paul,

Yes, I have read the PM and I'll get back to you :up: . Basically your thoughts are very much along the lines of what I already have but I wasn't sober enough last night to reply sensibly :oops: . I will get back to you via PM otherwise I'm hi-jacking your thread and I could write reams about my f/brake conundrum :D

Cheers Geoff
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Re: Lyster Suzuki T500 build

Post by smokin_blue »

I am looking for some suggestions. Does anyone have an electronic Tach they would recommend? I am running a Powerdynamo street ignition. My goal is to move away from the current cable driven method. I am looking at air filters since I will run on the street. I have concerns about pods based on comments people have made about tuning with them so I am looking at 3.5" diameter 4" long straight versions to get the airflow opened up. This however fully blocks the ability to run anything off the tach drive.
'07 Suzuki SV650
'90 GSX-R1100 streetfighter
LS650 powered custom framed café
'72 T500 with a Lyster frame
'69 T500-parts/project?
'83 GR650-project

Past bikes
'06 Triumph Sprint ST
'86 GSX-R750
'74 GT250/T350 custom
'79 GS750
'74 TS250
'81 TS100
Zunspec4
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Posts: 1051
Joined: Tue Dec 16, 2008 11:37 am
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Suzuki 2-Strokes: T500R, SV1000S, TS125, Seeley T500
Location: Trowbridge UK

Re: Lyster Suzuki T500 build

Post by Zunspec4 »

Hi Paul,

The most common electronic tacho you will see at UK classic race meetings is the SCITSU. It's sensor lead is laid alongside the HT lead(s) (I use small cable ties to secure). The unit itself can be powered one of 3 ways:

1. Internal re-chargeable battery (has to be returned for replacement if it fails)
2. External PP3 battery connection
3. From the bikes own wiring loom/power

Image
Image

I have used these with the PowerDynamo ign. with zero problems.

Cheers Geoff
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Re: Lyster Suzuki T500 build

Post by jabcb »

We had the same problem with pod filters on our GT250 cafe build. K&N angled tapered pod filters worked. Have enough room for the stock tach cable when the pods are turned a bit so that they almost touch each other.
ImageCafe-GT250-0649 by jabcb, on Flickr
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