Suzuki 2 Strokes

Installing the crank is a bit fiddly.
cafe-T500-2035 by jabcb, on Flickr

Crankcase assembled.
cafe-T500-2036 by jabcb, on Flickr

Installing the motor. The motor was light enough for me to do this by myself. Didn’t even try to pick up the GT550 motor — I just helped my mechanic friend install that motor. (I picked up & installed the bolts.)
cafe-T500-2037 by jabcb, on Flickr

Making headway.
cafe-T500-2057 by jabcb, on Flickr

And the crank on the 500 is almost 3kg heavier than the 550! Honest - my mate had just had his T500 crank done when he called a few weeks ago, and I just happen to have a freshly reconned 550 crank in the garage, so we compared them!

We did the GT550 cafe motor a while ago. I was surprised at how heavy the T500 & GT500 cranks are. I don’t remember the GT550 crank being that heavy.

Am a bit curious how the weights of mostly complete bottom ends compare. With mostly complete being the assembly you have to pick up to install the motor.

Never thought to weigh a 550 motor until it was in the frame. If I ever do another I'll try & remember!!!

The motor install was actually easier than I was expecting. The T500 uses 12mm bolts. I started with an old GT550 10mm bolt that made it a lot easier to line up the motor & install the bolt. With the crank resting on a piece of wood, you don’t have to maneuver much weight to get the first bolt in.

Those cordless torque wrenches are sweet. A great Christmas gift if you don’t have one.
The torque wrench loosened the clutch bolts & nut without doing anything to stop the rotation of the clutch!

Fingers on the 12-finger GT500 clutch have a fair amount of wear. Just took a look at the 18-finger clutch on the spare 73 T500, and wear is a lot better. Will use the 18-finger clutch.

The spare motor with the 18-finger clutch.
cafe-T500-2058 by jabcb, on Flickr

The GT500 12-finger clutch wear.
cafe-T500-2059 by jabcb, on Flickr

Mild fi,e usually sorts that. I've worn a few out! Wheelies are a barsteward on clutches.. .

Making headway.
The EBC 18-ear T500 clutch tool is NLA at this time. So I used an impact wrench.
cafe-T500-2062 by jabcb, on Flickr

Also got this neato piston circlip install tool. A bit pricey for a single-purpose tool. Plus the tool is for a specific wrist pin diameter.
cafe-T500-2061 by jabcb, on Flickr

Found it to actually be as easy to use as this video suggests. https://www.youtube.com/watch?v=lgB2WoQbt_Q
I’m using Wiseco pistons. This video shows how easy it is with these pistons. https://www.youtube.com/watch?v=2G8FVtMzGAk&t=37s

The company website: http://www.buxtools.com/product_catalog.php

Natty bit of kit, but getting the sods out is usually the problem unless there's a sticky out bit to grab.