Before I proceed on T500

mymechanicsucks · Post by **mymechanicsucks** » Sun Oct 04, 2009 10:14 pm

First I am thankful to be added to the forum, it has been a while that I have tried to join, second I have couple 70 t500 engines and a sheet load of parts but am new to the whole mechanic scene. Got taken for over$800 by dudes who seemed to know what they are doing but coulldn't seem to _____ there way out of a wet paper bag. So now it is me to make this beast roar again. So I did the leak down test and got air out the breather and have the cases apart from 2 engines. The gears in one set are imaculate no wear and super clean but the pistons are ceased in that set. First off will a bottem set of cases match to a top set of another , I would like to use these gears(onceI do the oil mod) but should I get both machined.. i would like to avoid that if possible but I cannot have another spring go by without my 2 stoke making the world a better place.

Second one of the carbs floats are leaking(taking on fuel) canI just solder the crack of will that throw off the adjustments. I assume it is air volume versus weight and adding solder would screw that up but again my mechanic sucks and that is me so I need a bit of direction.

Thanks

Jerry

rbond · Post by **rbond** » Mon Oct 05, 2009 8:21 am

Unless you have a broke/badly cracked cases, why do you want to use a different case bottom? If both cases are OK, it won't matter which gears are bad or good. Put the good set of gears in whichever case you want. You should be using new seals and gaskets anyway, so it won't matter which cases you use. If the cylinders/pistons are good from the other engine, bolt them up to the good case/ transmission. For the carb problems, it would be best to rebuild both with new jets, floats, etc. The parts are still available and not that expensive. Believe me it will be much better now and for later to do a full rebuild on the carbs. It is not as bad as it seems, simply because they are 2 strokes, so you can be up and running fairly quickly. I have a GT500 so I am pretty familiar with a T500, plus these guys are great here for more info/ advice you will ever need. Post more, we are already interested in helping out another Suzuki 2 stroke person get back on the road!! Good luck! Robert

jkevinlilly · Post by **jkevinlilly** » Mon Oct 05, 2009 3:24 pm

I don't know much about the T500, even though part of one is temp in my possesion prior to heading on to several locations. I rebuilt a 76 550 a couple years ago using the bottom case of one engine, the top off another, without a problem, so far... But it is best to use matching halves if possible. I have never patched a carb float, but several of the guys here have and can give you pointers on it.

Kevin

Post by **Suzsmokeyallan** » Mon Oct 05, 2009 3:36 pm

Ok ill tackle the float first, you can inflate it with some compressed air to blow out any dents it may have. Then clean and repair the leak with some solder but move quickly if not it may unsolder from other spots.
As for crankcases they are bolted together and machined in the factory for the bearing race holders so its best not to mix and match them if not you may get a looser or tighter than desired bearing crush value when the mismatched halves are torqued to spec.
This can cause binding or a bearing that may spin if one half is a micron larger or smaller on that section so try to avoid it.
Whats wrong with using a matched set of the cases you have and fit the best parts into that pair.

tz375 · Post by **tz375** » Mon Oct 05, 2009 4:10 pm

Guys, I read the post the same way at first but I think he's asking if he can use the top half (barrels and heads) off one bike on the bottom half, (crankcases gears etc) of the other motor.

jkevinlilly · Post by **jkevinlilly** » Mon Oct 05, 2009 8:07 pm

Uhh, tz, you may be right there, maybe we are thinking to hard.

Again.

If that is the case Jerry, then using the cylinders off of one bike on the crankcase of another one, as long as they are the same model/make bike is a non-issue and should not be a problem. Even if they are different years, a lot parts are still interchangeble on these old bikes, just check a parts micro-fiche to compare part numbers to see it they are compatible.

And by the way, welcome to the forum.

Kevin

mymechanicsucks · Post by **mymechanicsucks** » Tue Oct 06, 2009 7:36 am

Thanks for all the great advise first off, and yes I am actually talking about the 2 halves of the cases. Top half from one bike and the bottom from another. the one ugly bottom is still usable though I would have to heli coil a bunch of the holes and I didn't realize how expensive one of those kits was. Maybe I should and call it an investment. If I can get the seized jugs off the matching top case suppose that would be the best. Got it soaking in deisel right now hopefully it comes apart.

Part of my nature is to try to fix what I have before buying new but as for the carbs a complete rebuild sounds like a very good idea.

As for parts my local shop is not interested in my business AT ALL. As soon as they have to look something up in a book, or try to check status of a part number, their job instantly becomes getting me out of the shop and banishing my existance from their collective conscious. Where are some good online places for parts?

Much Thanks

Jerry

tz375 · Post by **tz375** » Tue Oct 06, 2009 8:11 am

Hi Jerry,

Sounds like I am the one person to misunderstand your post, but now we know.

Generally it is better to use a matched pair of upper and lower cases. In general British engines were machined in a way that made it imperative to use matched cases. The consistency of machining all but eliminated that problem and Honda for example would sell one crankcase halves separately, so they think it's OK to mix and match.

I come form the same school of fix it and use it, and sometimes it costs me more money as well as time than it's worth, but it's in the genes and I hate wasting anything.

The biggest problem with modern dealers is that they work to the book and there are no times for old bikes that need rebuilding and troubleshooting. It's just the way it is. And if they put you on the clock, the cost would be prohibitive.

A dealership is a business for most owners and they need to minimize their costs and that means getting bikes in and out of the service bay fast. We used to know our local dealer really well and he treated everyone as his best friend. Great service, good pricing and we told everyone that listened to go there.

He really understood what the business is about and he made a tidy sum when he sold it a couple of years later. Every owner after him failed to grasp what the business is about and it got smaller and smaller even through the boom time and it eventually closed.

It's rare to find a good dealer, so if you find one, hang on to them.

Parts are available on-line from

www.Bikebandit.com

alpha sport (not sure about the URL)

Ken at KnK

jkevinlilly · Post by **jkevinlilly** » Tue Oct 06, 2009 4:07 pm

Another good online source is http://motorcitypowersports.com/fiche_select.asp
Their parts department is really good to work with. I once ordered off them and the rings never made it to my house. As soon as I let them know they immediately shipped another set, and took it up with the shipper, I didn't have to do a thing.

I still buy most of my parts off the local suzuki shop, but I realize they will not have what I need in stock. I walk in knowing the part, and knowing if it is available, with the part number on a piece of paper. Within a couple days I get a call, pick the part up, and avoid the shipping cost.
As for service at the local shop, they are over run with servicing, primarily for four-wheelers. I checked with them this summer on getting a broken exhaust bolt extracted from a cylinder and was quoted a six week wait till they could get to it. When I wanted two tires mounted and balanced, if I provided the new tires, tubes and wheels already off the bike the quote was $75. Did it myself in about an hour.
And frankly, when most of the mechanics there are younger than my bikes, and have never seen a running two stroke streetbike, I just don't get a warm an fuzzy feeling thinking of them working on them.

Kevin

Post by **Suzsmokeyallan** » Tue Oct 06, 2009 5:50 pm

Jerry where are you located???, luckily i have a very good relationship (over 20 years) with a part owner of a dealership in Miami.
Here i get excellent service, i email him my wish list of parts and i get a reply on prices/availability within a day or two.
If i was buying a new bike this dealership would definately get my business.
I have to agree with the posts though, most dealerships today are places you feel lost in and at your wits end for getting proper service or parts.
If you are not sure of what you need in the slightest way you'll get turned around so easily by young parts persons who just want you out of their face.

mymechanicsucks · Post by **mymechanicsucks** » Tue Oct 06, 2009 10:39 pm

Western Canada. The last guy I took my bike to is supposed to be a very good 2 stroke guy but is in high demand for quads and snowmobiles so the couple hours he spent not finding floats full of fuel and seals that couldn't hold an ounce of pressure disqualifies him for future.

If it is gonna be broken and in pieces better it be at my shop where at least I will appreciate it.

Thanks alot for the links- got real excited about that bike bandit, only glanced over it but will definately have to check it out more and the others as well

Suzukidave · Post by **Suzukidave** » Wed Oct 07, 2009 4:06 am

This shop was also posted to the list recently and has a good on line parts finder . Look under OEM parts finder on the side bar list http://www.yamahaoftroy.com/default.asp

Post by **Suzsmokeyallan** » Wed Oct 07, 2009 5:09 am

Western Canada??, excuse my sarcasm here but thats not exactly a small region.
That means you should be Alberta or B.C somewhere, theres plenty of folks on here who can point you in the right direction who live in that region.

mymechanicsucks · Post by **mymechanicsucks** » Wed Oct 07, 2009 6:45 am

Sorry just used to being vague South Okanagan, Kelowna BC

Post by **Suzsmokeyallan** » Wed Oct 07, 2009 7:09 am

Ahhhh my favourite part of B.C, i absolutely love that region. Whoever says they dont like the Okanagan has got to be lying.
I passed through Kelowna last summer and saw so much development in the city i was amazed and shocked at the same time. They need to be careful with those high rise office buildings if not it will soon resemble a major corporate centre and not the tranquil little town it used to be.
Next summer ive got some plans for a B.C trip and another shot at Vancouver and the big island.
So we shall see how it all plays out, maybe we can pass by you for a quick hello.