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

[PeWe]

Good looking seat!
For your ass only.... Like a Bond movie...

[MauiK3]

The shocks are EBay?
Chinese?

[Terry in Australia]

Ha ha, I just had a mental picture of the beautiful young Sheena Easton singing, "For your ass only" as I ride after a villain wearing my immaculate dinner suit, on my equally immaculate T500 with a young Sheena on the back. Nothing could be further from the truth of course, but it doesn't hurt to dream.......

Steve, yep Ebay Oz shocks, from "Jap Bike Spares" in Queensland. Chinese I presume, but probably better than the OEM suckers that were pretty bad back in the day. The shocks may go on the T350 and I might put Ikons on the T500 yet, after my ride yesterday, I was once again reminded that the T350 OEM shocks are somewhat lacking and definitely not up to my favourite backroads.

[grcamna2]

Lol 

[RAFster122s]

Terry, I picture it with Blondie singing “One Way or Another…”

For me it would be Shania Twain “I’m gonna getcha good”

[Terry in Australia]

Thanks for those David, two other exceptional women performers, I have a couple of their albums in my Ford Territory from when I was doing my weekly 1000 mile commute from 2015-17. I enjoyed many miles bouncing around like a loony to their music to stay awake on the boring 400 mile drive each way to and from Canberra each weekend.

[Terry in Australia]

But like with any of my builds (I don't like to call them "restorations" because that infers that I'm returning my bikes to "As new" condition, and while mechanically that might be the case, but definitely not aesthetically) the first couple of weeks while I'm waiting on parts is the most boring, as I try to find things that I can do until the never-ending (or so it seems) trail of boxes start arriving. The seat cover was a bonus, but not much else, so far.

But that's OK, there's enough bits here to keep me going. The tank has been painted at least twice, and for some reason had body filler on top that hadn't been finished. I think the tank was originally blue and white, although it might be different when I remove all the paint underneath. In my experience, a lot of guys will strip the paint back to bare above, but only pay lip service to the paint below, so often the bottom color is the OEM color. Anyway, I used my nylon strip disc ion my angle grinder to remove the bulk of the paint, then used some chemical stripper to get into the parts I couldn't reach with the strip disc.

T500 Monday 16 Aug 2021 by Terry Prendergast, on Flickr

T500 Monday 16 Aug 2021 1 by Terry Prendergast, on Flickr

I had some leftover etch primer from my K0 build (wow, I was in lockdown when I built the K0 too, there's some deja vu for you, I think this is bike number 4 or 5 (if you count my unfinished Kawasaki builds, more like 7) since Covid changed our world?) so I gave it a good coat as it's been raining on and off, and my (almost) shiny bare metal tank wouldn't look as good tomorrow.

T500 Monday 16 Aug 2021 2 by Terry Prendergast, on Flickr

I've bought a set of PDR ("Paintless Dent removal") tools as I'd like to push the dents out rather than just fill them with bondo before I paint it, but that depends on how long they take to get there. Only baby steps right now, but I'll get there. What was nice was that Lyndon (Krusty) sent me a T500 dealers parts manual and a couple of sets of NOS points for free, which was a really nice gesture. You meet the nicest people on a Honda forum....

T500 parts manual by Terry Prendergast, on Flickr

 

[ekpent]

 Probably had this color scheme. I had one in that color once but it was really rough.Sold it on one of my purges quite some time ago.

[MauiK3]

That's going to be a great bike.

[MauiK3]

Forgot to ask, which paint stripper do you use?
Also, post photos of dent tools when you get them.

[grcamna2]

Probably had this color scheme. I had one in that color once but it was really rough.Sold it on one of my purges quite some time ago.

I like that color 

[PeWe]

That Suzuki blue not that far from Terrys F2 that got a Mazda Miata blue.

[Terry in Australia]

Thanks guys, it's coming along quite well considering that it's only early days. We're back into cold wet winter weather again this week so I need to look at the forecast for the next week to see when I should take my frame over to the blasters to get 47 years of paint, grease and crud blasted off (well, I'll need to remove the grease first) and get it home in weather good enough to at least etch prime, if not paint it, just to stop it from rusting again.

The parts are slowly starting to roll in now though. I received a care package from Cruizinimage today with new 1mm oversize pistons and rings, needle roller bearings etc, new throttle, clutch and front brake cables, carb manifold rubbers, airbox to carb rubbers, clutch plates, brake pads, chain and sprockets, and fork gaiters. They didn't have speedo and tach cables, so I've ordered them from Britain, along with the same decal kit as the one on that beautiful T500 of Eric's.

T500 parts drop 17 Aug 2021 by Terry Prendergast, on Flickr

T500 parts drop 17 Aug 2021 1 by Terry Prendergast, on Flickr

I'm still deciding on color, the blue is nice and Per is right, it's close enough to the Miata blue that I might use it if I go blue, although I think a couple of shades darker would look better, even if not particularly original. More to follow.  

[grcamna2]

Terry,T500 parts more plentiful than T350?

[Terry in Australia]

Thanks Bill, used parts certainly are as the T500 engine hardly changed in 10 years of production, whereas the T350 production stopped in 1972. (3 years in production) Cruizinimage have a few parts for both bikes, but sadly it’s not a one stop shop for T500 or 350 bits, although there is a lot of NOS stuff around, and a few people are making reasonably good aftermarket parts for them. I’m trying to find a better kick starter pedal for my T350, and have just discovered that they’re the same as the T500 kicker, but for some reason it’s hard to find one for the T500, T350 or even the GT500, which has the same pedal.

Same/same for a gear pedal, the only one on Ebay is in the US, and it’s damaged. I’ve bought a crappy Chinese generic pedal that might work until I can find an OEM one.

[RAFster122s]

At least it isn't an obscure old British or German bike that few exist today and you spend years searching for parts to rebuild it.

Blue is a nice color on bikes and Suzuki did some nice two color Blue and White schemes over the years.

The cold wet weather will be breaking soon Terry and you will transition to nicer weather.

After the T500 are you going to finish the Kawa's are is something else have your attention first?

Good to have the melted plastic finally arriving...

Anyone you know in US that has T350 or T500 stuff you could ask for sources or if they have good gear pedal or kickers available?  Would the fellow with the big lot of T500 stuff help you out for a couple hard to find parts you seek?

[Terry in Australia]

Thanks David, I’m slowly collecting parts for my early 1950’s BSA C11G 250, and parts are easier to find for it than they are for the two Suzuki’s, I just bought a huge pile of parts from a cop here in Melbourne who couldn’t give them away, I was lucky to only see the FB advert when he’d dropped the price 3 times after no bits at all, so I made out like a bandit. I never really had a desire to own a C11G, but Spotty made me buy it, and wouldn’t take “No” for an answer.

I will ask Keith if I get desperate, I’m lucky that I have 90% of what I need for the T500 on the way, and so now I just have to wait until stuff arrives. I have a pile of parts of parts arriving today and tomorrow at my delivery address in Florida and a pair of nice wheels, speedo and tach somewhere between Florida and here that should arrive in the next few days, so it’s happening.

I’ve just had my second Astrazenica jab so hopefully I’ll develop some super powers in the next few days? And yes, the Kawasaki’s need to be put together, I may never be able to get my ‘77 Z1000 in the road legally, but the Z1-B needs to be a runner. I’ve sold my VFR750 sadly, it’s being picked up tomorrow and the good thing is that I reckon I have room for 3 nore bikes at my storage place now, so the CB750A and maybe a couple of my garage ornaments can go over there and give me a bit more room here.

Once summer comes along the wife will kick me out of my winter workshop so I need some space to stash everything.

[ekpent]

  The bike I pictured Terry was just a stock photo I plucked off the internet. The same one I had and sold was quite rough and never got the love like your doing to yours. Way to stick with it ,little something everyday it seems.

[jaytee-nz]

Terry, are these T500 ? They are both the same and genuine Suzuki but I have no idea what model they are off.
If they are you can have them.
One on the left has good chrome other than a patch that has worn off.

[grcamna2]

Terry, are these T500 ? They are both the same and genuine Suzuki but I have no idea what model they are off.
If they are you can have them.
One on the left has good chrome other than a patch that has worn off.

They certainly look like it.

[Terry in Australia]

Terry, are these T500 ? They are both the same and genuine Suzuki but I have no idea what model they are off.
If they are you can have them.
One on the left has good chrome other than a patch that has worn off.

Fark! Yeah mate, looks like the real deal, yes please! Let me know how much to ship to Melbourne (3082) and I'll zip some cash your way! Thanks!

[jaytee-nz]

Ok, no problems. Only thing is NZ has just gone in to a nationwide lockdown as someone decided to bring back Covid Delta from NSW and it looks like it's spreading fast.
As soon as the lockdown is over I'll PM you and sort things out for you.
I've also noticed that they both spin around and don't lock in to position but it's probably just the ball bearings missing. I'm sure a man of your skill can sort that out,
Cheers - John.

[Terry in Australia]

Well as Eric's suggested, my whole bike building method is to try to get a little bit done each day, and a bit more on weekends. Today I had to do some running around, my VFR750 has gone to it's new owner, the guy I bought the big pieces from to build my K0, in Brisbane. He's not gonna receive it until the 30th, but like me (and probably you guys) he's already bought some parts for it, that he won't need. Anyhoo the VFR is gone and I'm already missing it, it is a fantastic bike, and I know I need to downsize, but if another one comes along one day, well.....

VFR750 Farewell 18 Aug 2021 by Terry Prendergast, on Flickr

VFR750 Farewell 18 Aug 2021 1 by Terry Prendergast, on Flickr

So there I was, crying uncontrollably when I remembered that I had to go to my weekly physiotherapist appointment. I have a new physio, another lovely young thing who was happy to continue with my weekly therapeutic back massage. As soon as she starts try to get me to do pilates, I'm walking, but for now, I'm a happy old man.......

So bottom line is I didn't get much bike time, but I did strip the paint under the tank. Most chemical strippers available now are crap, but an Aussie branded "Septone" stripper, sold at "Supercheap Auto" is fantastic stuff. It's a gel, so I brushed it on and let it sit for a couple of hours, it's no good in summer, it'd dry out pretty quick, but it was pretty cold again today, so was still nice and wet when I came back, and gave it all a good scratch with a toothbrush sized wire brush, just to make sure that the stripper had eaten it's way down to bare metal.

I then hit it with the hose, and was happy to see that the old paint was just a memory.

T500 Wednesday 18 Aug 2021 by Terry Prendergast, on Flickr

As you can see, there was a little surface rust, and I did think about dropping it in my phosphoric acid bath, but decided it wasn't necessary, so instead I cleaned it with some 240 grit dry sandpaper and then cleaned all the dust off, wiped it over with acetone, and hit it up with some good ol' Rustoleum satin canyon black.

T500 Wednesday 18 Aug 2021 1 by Terry Prendergast, on Flickr

Tomorrow I think I'll pull the forks and springs out of the phosphoric bath and install the new gaiters after I paint the bottom triple. I don't have the fork seals yet, but I need to be able to roll the bike around when the wheels turn up, so I'll do them later. More tomorrow.
   

[Terry in Australia]

Ok, no problems. Only thing is NZ has just gone in to a nationwide lockdown as someone decided to bring back Covid Delta from NSW and it looks like it's spreading fast.
As soon as the lockdown is over I'll PM you and sort things out for you.
I've also noticed that they both spin around and don't lock in to position but it's probably just the ball bearings missing. I'm sure a man of your skill can sort that out,
Cheers - John.

Thanks John, that'll be great mate, sorry to hear about the plague spreading from NSW to NZ, I hope it doesn't get out of hand, I've got a son living in Bondi Junction, across the road from where it all started and he's locked himself in his apartment with his cat, and doesn't come out unless he absolutely has to, but can't believe the amount of idiots wandering around aimlessly without masks on. I'm not surprised that the situation in NSW is getting worse. Having said that, we've just celebrated(?) 200 days in lockdown here in Victoria, since March last year. Not much to celebrate, sadly.

[MauiK3]

+1 to stripper is terrible. My Citrus Strip that I use is fairly good if you give it time. Some that I've tried don't seem to do much. I've found that straight Simple Green in my ultrasonic, heated, takes paint off too. It also works cold but takes a lot longer.
Nice looking tank, very sound.
Maui has had a huge Covid spike too. Tourists here don't seem to think there is a pandemic. We just stay away.
One mainland group we know of has planned a 100 person destination wedding here for early September. Really? I bet the wedding pictures will not be masked people grouped together. Rules are tightening, we wonder how long they will go until they restrict tourism again. Maui is hooked on tourism like a junkie.