T500 5th Gears

[Rustygt550]

Hi, I read somewhere cant remember where, a guy that makes or remanufactures T500 5th gears, does anyone know?

My own gears have pitting on them mostly the countershaft, has anyone seen this before my bikes a 1975 T500

Thanks

[Suzsmokeyallan]

Its all to do with a lack of lubrication and as such the updated transmission oil capacity and the oil dam retrofit from the factory is mandatory to prevent further damage to the parts.
Its not supposed to be happening to the 75 model engines as the issues were solved by then.
By the way how much oil have you been putting into the transmission??

[tz375]

Pitting is usually caused by rust and that's caused by moisture in the air and the bike sitting for long periods.

But if it's brinelling - where the outer surface is basically pressed into the softer material below - that is caused by excessive force, running without enough oil or poor heat treat or choice of metals for teh task. That's common on Kawasaki triple gears.

If the damage is chunks looking like they were dug out of the tooth surface, it's probably cheap oil that broke down.

Overheating is usualy easy to see with blued gears.

Any pics we can see?

[diamondj]

Bear in mind, while Suzuki fixed the oil capacity issue on the T500 by increasing the height of the wall around the "dead space" inside the trans, they NEVER changed the position of the oil level plug. So you could add 1400cc's and then curse yourself for overfilling the bloody thing while 200 cc's of oil you need drain out of the fill level plug.

Jim

[CJF]

Hi, I read somewhere cant remember where, a guy that makes or remanufactures T500 5th gears, does anyone know?

My own gears have pitting on them mostly the countershaft, has anyone seen this before my bikes a 1975 T500

Thanks

Two options I know of for a replacement 5th gear. I've seen them on UK Ebay recently, so try searching there. The other option is Moore Performance Engineering..try this link http://www.mpe07.co.uk/. I think he makes them for 60 pounds each (the conversion rate hurts a little). Send him an email to check out the pricing.

[argo1974]

GTReiner should have them on stock.

[Rustygt550]

Thanks

I will post up pictures soon.

I dont know the history of this bike as i bought it as a non runner.

I wonder should I be looking for a complete used transmission rather than trying to source parts to fix the one I have.

Sounds Like another call to PM!

[Rustygt550]

I just bought complete gearbox internals from a guy off ebay here's hoping there as described!

[Rustygt550]

Well the used gear box arrived today all the gears were great apart
from the 4th cog on the counter shaft.

If anyone has a used counter shaft with no pitting I would be very interested!

[Rustygt550]

Just got back my T500 input shaft from Moore Performance Engineering.
He took off the damaged 4th gear cog made a new one & installed it on the shaft.

It is a excellent job With first class engineering!

I Highly recommend him

[CJF]

Great to hear things worked out well with him. I was considering a close ratio racing tran that he makes for my project. The price is a little high with the current conv rate, but still a few hundred dollars lower than Nova Racing Trans. Those two companies are the only ones I know of worldwide that produce this type of stuff on a regular basis for older bikes.

Best of luck with your rebuild.

[tz375]

The difference between Oily Tom at MPE and Dyson at NOVA is that Ellis (Oily Tom) does a lot of one-offs where NOVA prefer to do a run of say 10 or more of the same thing.

Both are top notch companies.