Topic: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.

[RAFster122s]

Hope your back forgives you...
Quite a bit of engineering today...hope it works out and the carb cable holds up and the throttles not snapping back is an easy fix.
It is always something when working on old bikes and rebuilding them...

Been seeing news about Melbourne and Australia and Covid.

[Terry in Australia]

Thanks David, I'm getting there. You've probably seen that Melbourne (where I live) has had the world's longest lockdown? As much as it sucks not being able to ride my bikes, I have really enjoyed "working from home" and sneaking outside to do little jobs, then walking outside on sunny afternoons (and on a few rainy ones) to do some bike work, with no 40 minute drive to and from work each day, no parking, no tolls, and sadly, no interesting meals. Oh well, 3 out of 4 aint bad......

[grcamna2]

Terry,you've run into more than your fair share of set-backs with the T500 during this time ! I would also be upset that new cables don't match the application,Ah aftermarket..  . Considering all those things thrown into the mix,you've made good progress and I'm glad to be subscribed.I hope your filter shows up soon so you can install the airbox;did the bike come with an original airbox 2 into1 rubber boot? I remember seeing one in a pile of parts,I hope it is still good to go. 

[grcamna2]

Thanks David, I'm getting there. You've probably seen that Melbourne (where I live) has had the world's longest lockdown? As much as it sucks not being able to ride my bikes, I have really enjoyed "working from home" and sneaking outside to do little jobs, then walking outside on sunny afternoons (and on a few rainy ones) to do some bike work, with no 40 minute drive to and from work each day, no parking, no tolls, and sadly, no interesting meals. Oh well, 3 out of 4 aint bad......

I hope more folks get vaccinated and they lift your lock-down soon.

[Terry in Australia]

Thanks guys, well the weather is all over the shop today. The forecast for the next week is rain every day, but the weather forecast is just as unreliable as the weather itself, so I have no doubt that in a couple of days it'll be nicer, hopefully.

It rained nearly all day today, and the wind howled in sideways, so even though the back of the T500 is a good 10 feet inside my patio, the rear fender got wet. I wasn't going to even venture out this afternoon, but suddenly the sun came out and the wind dropped, so I raced outside and wired the coils (cut the harness off the old coils so I could plug them into the harness) but I hadn't even shortened the plug leads and fitted the new NGK caps when the sky got dark again, and the rain started coming in sideways. Poop.

T500 Monday 4 Oct 2021 by Terry Prendergast, on Flickr

Oh well, they llooked good. So good in fact that I thought I might run the main wiring harness. I rolled it out, but couldn't work out the orientation because none of the plugs matched? Fcuk! It's not the right harness! Yep, it was advertised as being for a type I, II and III T500, but it's not the one I need for my bike. I'd jump up and down, but that won't get my bike finished sooner, so I'll either cannibalise it and use the plugs from the crusty old harness to make a new harness, or just hotwire the ignition circuit so I can start it and ride around the block while I'm waiting for a new harness (that I haven't found yet) or I'll keep it as is, because it will fit my T350, and I don't know how good the crusty old T350 harness is as I haven't connected everything yet.

T500 Monday 4 Oct 2021 1 by Terry Prendergast, on Flickr

Regardless, it'll be running soon, and that's all that matters. Good thing today was I can't see any oil leaks from the oil tank, pump or lines, so that's a good sign, plus the new Motobatt battery arrived today too. Hopefully, weather permitting, I'll get more done tomorrow.  

[RAFster122s]

Well, it is definitely spring there...showers and unpredictable weather.  We actually have been having some cooler temps, but today it was in the mid 90s this afternoon. I have been riding my MC as much as possible and rode to church this morning. Helped out at one of the areas we have for groups and stayed a couple services leaving around 12:30 and temps were up to 93f. The humidity was down today and it felt nice in the shade dressed in shorts...but in the sun in black armored textile pants and a armored white and black textile mesh jacket it became a bit warm with the stops for traffic lights. At least no one tried to run me over or was tailgating today.
By the time 40 minute ride got me back across town to the NE of Tucson it was pushing 94-95 and felt warmer. I detoured for lunch and relaxed in AC. Ride home wasn't as much fun as Ina road is not a nice road for traffic. By the time I got out to Picture Rocks Rd traffic was very light again and I could enjoy the curves and elevation changes of the Saguaro National Park West going through Picture Rocks Pass. Unloaded the bike, put it away, and came in and stripped off the MC gear and sweaty garments and cooled off.
The sun is very intense in the desert SW...

Bike needs to be washed and time to clean the chain and lube it.
Maybe it will get waxed too...

Terry, your weather will stabilize. Sucks that the harness was wrong. Could you buy a terminal & connector block kit for the harness and salvage it replacing the connectors? If you cannot source another? Z1 parts have a harness?

[Terry in Australia]

Thanks David, as my 93 year old mother keeps telling me, "We'll be complaining about the heat soon". Not sure where I can find another harness but not too pissed off, I have two originals that might be salvageable, I never throw anything out until I've finished a build so I'll pull them out tomorrow and see what I can make out of them.

[Zunspec]

Hi Terry,

My parts book lists the Wiring Loom 1 as P/N 36610-15103 for models T500R thru L (36610-15104 T500M).  Here's a copy of the T500 Wiring diagram, it's good for the above models of T500s.

Cheers Geoff

[Terry in Australia]

Thanks Geoff, I'm colour blind, but that diagram is so bright I imagine I'll work it out.

[Zunspec]

Thanks Geoff, I'm colour blind, but that diagram is so bright I imagine I'll work it out.

LOL, sorry about that Terry.  I can't locate one with a colour key to go with it.  I guess whoever made this one didn't think it would need one 

Cheers  Geoff

[ekpent]

 He's calling it a 15103 but is it the same as what you have Terry that doesn't fit ?  https://www.ebay.com/itm/274885887656?epid=1827803704&hash=item400079c6a8:g:fboAAOSwYLBhBHa7

[Zunspec]

One item I have yet to find and that is a NOS or Repro wiring loom for the T500.  I've only been looking for 10 years .  In contrast I could shake a stick at the number looms available new for my 1966 Triumph.

Cheers  Geoff

[grcamna2]

Terry,I hope you're able to make use of one of your used ones after cleaning-out each connector and removing as much corrosion from them as possible.I suppose(if it was me)I would return the new harness and hope to somehow find an NOS if at all possible.

[Zunspec]

He's calling it a 15103 but is it the same as what you have Terry that doesn't fit ?  https://www.ebay.com/itm/274885887656?epid=1827803704&hash=item400079c6a8:g:fboAAOSwYLBhBHa7

Looking at a few parts fiche's (and my parts book) -15103 is good. The -15102 in Terry's photo is a T350 loom. but is the same as the loom for the T500 Mk1/11's (early bikes).  Just to confound me CMSL (Netherlands) have a NOS -15103, I obviously didn't search effectively enough.  Maybe the price at 259 Euros put me off lol.

Cheers  Geoff

[Terry in Australia]

Thanks guys, I’ll hang on to the new one regardless, who knows when another two stroke Suzy will drop into my lap? I’d love a Cobra? The wiring harness for the coils was in surprisingly good condition when I chopped the wires off to attach to the new coils yesterday, as you’d expect the wires were coated in a layer of 2 stroke oil mist and grime, but cleaned up nicely with a rag soaked in acetone.

Gotta love working from home, I just wandered outside and pulled the two old harnesses out of a tub. Interestingly one is correct for my 1974 T500 “L” and the other is the same as the one that I bought, but I’m pretty sure that I pulled both of them off the two frames that are both 1974 T500L’s. Go figure. The correct one doesn’t look too horrible so if I give it a cleanup it might do the job.

It would have been nice if they were both correct for my bike as there are some busted plugs, but I don’t remember if they are the common plugs that I have plenty of, or the unique (to me) “L” plugs. I’ll post some pics when I brave the misery that is today’s weather and get stuck into it. It would be nice to have it wired for ignition at least by close of play today.

[Terry in Australia]

Well..........

T500 Tuesday 5 Oct 2021 by Terry Prendergast, on Flickr

But it wasn't that bad, in fact it was great. I took to the wiring harness with my rag and bottle of acetone, and was happy that, apart from some plastic plugs that are so badly degraded over time that they've gone brittle, the harness was pretty much intact. I did have to laugh though, when I cracked open the fuse holder to see if there was a fuse inside it, and saw this:

T500 Tuesday 5 Oct 2021 1 by Terry Prendergast, on Flickr

Yep, any old smoker will recognise this, the foil out of a cigarette pack wrapped around the fuse when you blow a fuse and don't have a spare. I haven't had a cigarette in over 6 years, but probably still have some cigarette pack foil in the pockets of my bike jackets from "Back in the day". I couldn't remember how many layers equals 15 amps resistance, so I replaced it with something a bit more modern.

T500 Tuesday 5 Oct 2021 2 by Terry Prendergast, on Flickr

Yep, those aren't fuses, they're 15 amp circuit breakers, which are really handy if you blow a fuse and don't have a spare out in the middle of woop-woop, with no gas stations nearby, and no cigarettes. I ran the harness along the top of the frame and bolted the regulator and rectifier in place, and connected all the plugs. I had to make up new battery cables because I didn't have any, and the rubber mat for the battery box is long gone, so I used a piece of hardware store rubber strap to wrap the battery with before putting it in the box, and with the fat negative lead making it a tight fit in the box (so tight I had to grab the battery with vice grips to pull it back out) I've decided that I don't need to make a battery box door. (missing also)

T500 Tuesday 5 Oct 2021 3 by Terry Prendergast, on Flickr

Well, the battery was in it, so I turned the key and with the plugs out kicked it over, and noticed that only the left plug was sparking. What the hell, one's better than none, so I hooked up a temporary fuel tank, gave it two kicks, and it ran! But only on one cylinder, so I've either got a bad set of points, or condensor, or maybe even one of my new coils is bad. I was running out of light, so I put it away, but was happy that it started up and ran so easily, even if only on one cylinder. All going well, I want to be riding it by the weekend. Who knows? Maybe I will. More tomorrow.

T500 Tuesday 5 Oct 2021 4 by Terry Prendergast, on Flickr

[ekpent]

Fire in the hole !!

[grcamna2]

Terry,you have fuel in both carbs?

[Terry in Australia]

Thanks guys, and yes Bill, it's not a fuel problem, it's a lack of spark issue. This morning a package from New Zealand arrived with two kick starter pedals that John sent me, and wouldn't even let me pay for postage, thanks mate, I owe you, Krusty and Trevor each a beer, or 10! I whipped off my kicker pedal and made a better one using the bottom section of one of yours with the top section of mine, and installed it again. I got so excited I kicked the big lump over, and it started right up, on 1 cylinder again.

I removed the points cover and found one loose (but not disconnected) wire to the offending set of points, so I reckon that's where the problem lies, but I might swap out the points and condensors while I'm at it, one set at a time just to see if that fixes the issue, I've definitely got power to both coils, so I'll assume, for the time being, that both coils are fine and further posit that it's a duff wire from the points or condensor.

I discovered a little trick with my test light, with the engine running, if I earthed the light to the frame and poked the probe to the power terminal wire on the coil I got a constant glow, and if I poked the signal wire terminal on the coil, on the coil that was firing, I got a "flashing" glow, whereas on the coil that wasn't firing, it was just a constant glow, which tells me that there's no signal coming from that set of points to the coil? I think that's right, anyway.

I was blithely kicking away, when the kickstarter pedal ceased to engage. Fcuk! I had the same problem with the T350, and it wasn't a big problem, the spring loaded pawl wasn't engaging inside the gear so I was able to fix it just by removing the clutch side engine cover off, pulling the gear, unsticking the spring and reassembling everything, no biggie. On a T500, no such luck, you have to split the cases, then try to find a NOS gear and pawl, if you can find one. Suffering as I do from anxiety, I did a search and found a shop called NOS Parts Now, and even though they didn't have a lot of parts for my T500 I was able to get a new gear, pawl and spring for $170 shipped to my shipper in Florida, so all going well, I'll have those parts in a couple of weeks. Until then I'll attempt to shock the kicker back into some semblance of serviceability by tapping, shaking and begging it to engage. Push starting might be an option, and of course I always wanted to build one of those angle grinder powered race bike starters.

I'm not looking forwards to pulling it apart completely, so for Geoff and Simon, can I just tip it upside down and split the cases to get to the starter gear and pawl, or am I better off removing the heads, cylinders, pistons, and top case? I'm guessing the latter, but any input would be appreciated.

At the moment I'm nursing a sore foot, I've broken both ankles over the years and this morning when the kicker slipped, I thrust my foot into nothingness, but that was enough to get me limping and swearing. (it doesn't usually take much to make me do either) When I finish work for the day I'll wander out and see if I can't make it spark on both cylinders.

[jaytee-nz]

I'm glad my kick starters finally arrived Terry, but it looks like they didn't bring you much luck in that department !
Being Kiwi items, they will of course be much stronger than the Oz parts they are "levering".
Congratulations on the start-up. Not far to go now.

[Terry in Australia]

What a wonderful day...........

[Terry in Australia]

I'm glad my kick starters finally arrived Terry, but it looks like they didn't bring you much luck in that department !
Being Kiwi items, they will of course be much stronger than the Oz parts they are "levering".
Congratulations on the start-up. Not far to go now.

Thanks John, sadly I'll have to pull the engine out again to fix the kick starter issue, or become really good at bump starting, maybe I can enlist the staff at the Heathcote Bakery to give me a push after I've had my lunch on my favourite ride? But anyway, yep, my foot hurts and I/m limping like an old(er) man, but you couldn't smack the sh1t eating grin off my face tonight. Thanks again for the kickers mate, much appreciated!

[Zunspec]

Hi Terry,

  sounding very nice, the Titan pipes are crackling well 

WRT the kickstart pawl - I can only advise that you remove the barrels and whip the engine out and split the cases to address the problem.  I've considered just removing the bottom case, leaving the top end in position, but honestly it's a bodge and more hassle than it's worth.  The T500 on points is easily bump started until the replacement parts arrive. 

Cheers  Geoff

[Terry in Australia]

Thanks Geoff, I think you're right, it's not a CB750 so not too painful, and I'll cheap out and use all the same gaskets, as that would be another nightmare waiting for new gaskets to arrive from overseas, lucky I didn't use any gasket sealant.

Now that I know that it runs, and appears to run well I'll continue bolting stuff to it and then just pull the engine again when the starter gear and pawl arrive. My right foot has blown up like a balloon so I don't think I'll be trying to start it for a few days anyway, (Morphine is a wonderful drug) I wish my NOS headlight ears would turn up so I can finish the front end, but in the meantime I'll busy myself with the tank, the petcock (I might pull it apart and see if the diaphragm is ok) fitting the tank and sidecover badges, etc. Oh, and I suppose I may as well install those new tyres, it's not like I don't have enough time.

It's gonna feel weird when it's finished, I won't know what to do with myself.

[PeWe]

Good progress Terry!
Look and sound fine. I can not feel the smell but most likely fantastic

You can use castor oil in that engine?
I used sometimes in my modified mopeds. It smelled fantastic and everywhere!!
Castrol had one or 2 oils.


You have more project to enjoy, Kawasaki's and CB750 970cc stuff, right?