Author Topic: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.  (Read 51348 times)

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Offline grcamna2

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #575 on: October 24, 2021, 03:28:46 PM »
That's a good successful day of wrenching, congrats on both wins.

+1 same.  :)
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  I love the small ones too !
Do your BEST...nobody can take that away from you.

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #576 on: October 24, 2021, 04:49:16 PM »
Hi there Terry.
Those 6mm  banjo bolts can strip the thread in the pump even if you look at them the wrong way. Heaps of kawasaki triple pumps with helicoils in them. The washers that replace the original aluminum crush washer are called stato -o -seals  or bonded washers just incase you weren't aware. Don't need much torquing down for a good result. 

I find that red castrol 2T oil easier to see than see through clear oil.

Offline Terry in Australia

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #577 on: October 24, 2021, 06:52:52 PM »
Thanks guys. Ken, yep I use “Castrol Red” (reminds me of my old friend “Marlboro Red”…) and it is much easier to see through my 50 year old lines. The Suzuki’s have plastic washers under the banjo fittings so are probably a bit more fragile, I did think about copper washers but as you’ve mentioned the threads are so soft in the pumps that you can’t torque the banjo bolts down tight enough to crush a copper washer.

Desert Refugee (and I hate calling you by that but I don’t know your name) yes, Wednesday is looking good for a ride herein Melbourne. I have to go to physio on Wednesday at 3pm so I might ride over there then continue on for a big lap around the metro area. ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline grcamna2

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #578 on: October 24, 2021, 07:00:45 PM »
Terry,at least you can bump-start the T500 and enjoy some of your labor.
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline Terry in Australia

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #579 on: October 24, 2021, 07:22:14 PM »
Yep it’s easy to bump start Bill, but I do have a fear of stalling it in traffic so the sooner my kick starter parts turn up, the better, and on top of all that, it’s just bugging me that I can’t complete the build until it’s properly fixed. In the meantime I have lots of other bikes to ride, so no biggie. ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline desertrefugee

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #580 on: October 24, 2021, 07:56:21 PM »
Desert Refugee (and I hate calling you by that but I don’t know your name) yes, Wednesday is looking good for a ride herein Melbourne. I have to go to physio on Wednesday at 3pm so I might ride over there then continue on for a big lap around the metro area. ;D

The name is Darrell. Thank you for asking, Terry. Here's hoping that Wednesday ride is a good one. Wait a minute - they are all good ones.

(Although I am unable to ride much these days, up until very recently I sure was. The funny thing is, after over 50 years of riding all manner of motorcycles, I still found myself excited the day and night before a planned ride. So much so, that it was difficult to sleep! Still the same exact emotions from 50 years ago.)
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Offline Terry in Australia

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #581 on: October 24, 2021, 11:51:00 PM »
Thanks Darrell, and like you, I really do get excited before a ride. Like other places in the world, Covid rules the roost, so if Victoria is 80% double vaccinated by this weekend, I'll be allowed to ride off into the countryside, so I'm trying to decide between my faithful K2 bitsa, or my 2300cc Triumph Rocket III to visit my 93 year old mother on the weekend.

As much as I enjoyed riding the K2 down last time, I'm keen to ride the Triumph because I bought new Tyres for it and had it serviced back in March, and haven't ridden it since, so it really needs a run. Like you I'll have problems sleeping the night before, but after the 200 miles to Bairnsdale and a few drinks with my cousin after dinner at my Ma's, I'll sleep like a log, then burn rubber all the way back to Melbourne on Sunday.

But of course I couldn't wait until the weekend when I realised that I had an opportunity this afternoon. The wife went shopping, so I quickly bolted the speedo back in place, wheeled the T500 up the driveway, bump started it, and did a tour of the neighbourhood. I bought this house in 2001, but in 1978 I moved into a flat (apartment) with a couple of other Army jerks one suburb over, and I haven't really ridden/driven around there much in the last 40-odd years, so it was fun to cruise my old neighbourhood on the Suzy, riding past my ex-girlfriend's house (her grumpy Italian father probably still lives there, if he's still alive, I probably gave him a few ulcers back then) and a few other girls I knew, and was surprised at how much the place hasn't really changed.

The bike went great, and blew happy clouds of blue smoke wherever I went. I was disappointed when a late model toyota pickup drove past blowing more blue smoke, and it wasn't even a diesel? The cheek! I had to catch up and ride in front of him just to coat him in some happy smoke. A guy pulled up beside me at the lights and told me that he liked my bike, and he had an old TS250, so I told him that mine was basically two TS250 engines grafted together. I should have asked him if he wanted to sell his TS250, but the lights changed, and we went our different ways.

When I got home I saw that I had a fine spray of something on both shoes, and I reckon that there's a bit of smoke coming out of where the header pipes go into the mufflers, and a bit of raw fuel has been blown out onto my shoes, because unlike oil, it disappeared as soon as the heat from my feet warmed the leather in my shoes, or something like that? There doesn't appear to be any oil in the pipe betwixt the pump and the engine, but I could see tiny bubbles of oil moving towards the engine, so hopefully my oil pump rebuild kit will arrive while my engine's apart and I can rebuild the pump while it's out, but if my luck holds true, it'll arrive the day after I reinstall the engine.

Oh, and the speedo doesn't work, bugger. Still, I'm not going to give up, I'll jack the front wheel off the ground and spin it, just to make sure the speedo drive at the wheel is actually working, I'm pretty sure I checked it, but that might have been the T350? Anyway, the T500 can take a rest while I wait to pull the engine, so I'll pull the wheels off and replace the tyres, fix the speedo, and dream about longer rides........ ;D   
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline grcamna2

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #582 on: October 25, 2021, 11:12:01 AM »
Terry,I'm glad you had a short 'shake down' ride on the bike;nothing like the sound & smell of a street 2-stroke !  8)
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline Terry in Australia

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #583 on: October 26, 2021, 07:40:15 PM »
Well the engine strip will be delayed by another couple of weeks, but that's OK. Since this build started I've been looking for a set of 1974 engine cases to match (as close as possible) my 1974 frame. While it doesn't matter to me that I technically have a 1971 engine in a 1974 bike, if I ever sell it, it may keep some buyers away.

A few days ago when trawling thru Ebay for parts I saw a set of "1976 T 500 Engine cases" for sale. I checked the engine number, and they're definitely 1974 cases and only 182 numbers apart from my frame number, so good enough to be considered "all original". I asked the seller (whom I've bought from before) for some more pics, and apart from the horrible black paint, they look good, so I bought them. They're being sent by UPS to Florida, then Fedex to me, so should be here in two or 3 weeks.

T500 1974 cases 1 by Terry Prendergast, on Flickr

I'll strip the paint off them and get them around to my mate Hussein for vapor blasting, along with some other engine covers I've bought for my second T500 project, then I'll strip my engine and swap the guts across to the 1974 cases. I've done some quick sums and it appears that this little side project will add close to another $1000 to the build total, I guess it's that "BOAT" thing, "Break Out Another Thousand"............ ;D 
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline RAFster122s

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #584 on: October 26, 2021, 07:51:50 PM »
Terry, I recall you needing to split the cases for the starter spring fix but why are you going to the trouble of changing the cases? Isit because of the crack or that they are a couple years off what they should be?
David- back in the desert SW!

Offline Alan F.

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #585 on: October 26, 2021, 08:00:15 PM »
Those cases should add quite a bit of value to the bike, I hope they arrive free of surprises.

Offline Terry in Australia

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #586 on: October 26, 2021, 08:12:16 PM »
There is one little crack that the seller, "Tree" (one of my old nicknames, coincidentally) pointed out, but I don't think it's a biggie. ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline Old Moe Toe

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #587 on: October 27, 2021, 01:35:15 AM »
There is one little crack that the seller, "Tree" (one of my old nicknames, coincidentally) pointed out, but I don't think it's a biggie. ;D

I have a cobber whose nickname is "Trunky" because he is meant to be hung like a tree trunk.
You must have an exceptional one Terry!. Haha

Offline Terry in Australia

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #588 on: October 27, 2021, 01:41:31 AM »
There is one little crack that the seller, "Tree" (one of my old nicknames, coincidentally) pointed out, but I don't think it's a biggie. ;D

I have a cobber whose nickname is "Trunky" because he is meant to be hung like a tree trunk.
You must have an exceptional one Terry!. Haha

Ha ha, thanks mate, no, when I was an Army Commando I was maybe the tallest and heaviest guy in my unit, (no fat back then) and one of the little guys called me "Big Tree", and it caught on. ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline MauiK3

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #589 on: October 27, 2021, 02:35:15 PM »
Oh, maybe others were assuming a different interpretation. ;-))
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Offline Terry in Australia

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #590 on: October 28, 2021, 01:26:52 AM »
Well I never told you why he called me "Big Tree", but that's a story for another time..... ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline PeWe

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #591 on: October 28, 2021, 03:49:12 AM »
Sure he, not she or them all? ;D
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Updates of the CB750 K6 -1976
http://forums.sohc4.net/index.php/topic,180468.msg2092136.html#msg2092136
The billet block build thread
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http://forums.sohc4.net/index.php/topic,168243.msg1948381.html#msg1948381
K2 engine build thread. For a complete CB750 -75
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Carb jetting, a long story Mikuni TMR32
http://forums.sohc4.net/index.php/topic,179479.msg2104967.html#msg2104967

Offline ekpent

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #592 on: October 29, 2021, 08:03:36 PM »
 Since your kind of on a 2 stroke kick Terry an early rider who was taming these back in the day on the race track just died a couple of days ago in a street crash on his motorcycle. He was Ducati legend Paul Smart who also raced for Suzuki,Kawasaki,Yamaha and I think a stint with Triumph. Bummer when an old pro at 78 gets it on the street. Those must of been the days of no fear on early big 2 strokes. Luckily tires finally caught up ! Here is one of many tribute stories.  https://www.motorsportmagazine.com/articles/motorcycles/paul-smart-1943-2021
  Paul Smart with brother in law Barry Sheene.
« Last Edit: October 30, 2021, 06:30:37 AM by ekpent »

Offline Terry in Australia

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #593 on: October 29, 2021, 11:42:00 PM »
Thanks Eric, that is a shame. Paul Smart made Ducati a much better known marque when he won Imola on Ducat's first L twin, the 750SS. A Suzuki T350 beat a similar Ducati at the 1972 Castrol 6 Hour here in Oz, so they weren't all that good, but Paul was a brilliant rider. ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline simon#42

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #594 on: October 30, 2021, 03:43:45 AM »
he was also a brilliant bloke . sad to see him go .

Offline grcamna2

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #595 on: October 30, 2021, 10:09:36 AM »
Terry,how's the project coming along ?
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline Terry in Australia

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #596 on: October 30, 2021, 02:29:13 PM »
Thanks Bill, well nothing much is happening mate as parts are still on their way, I did receive some rear footpegs, a sidecover badge, headlight mounting rubbers and new fuel line on Friday so I’ll install them in the next few days, but the next big thing will be when the engine cases arrive along with the kick starter parts.

We have a long weekend this weekend, 4 days off. It pissed down rain yesterday, the tail end of a massive storm on Friday that ripped out trees, took the roofs of lots of houses etc. one poor guy being interviewed on TV pointed out that in the last 2 years we’ve had devastating bushfires, floods, a pandemic, an earthquake and now this, what’s coming next?

Anyway the storm has fcuked off and the weather should be fine until Tuesday so today I’m taking my 2300cc Triumph for a 100+ miler to scrub in the new tyres I put on it in March or April, then tomorrow or Tuesday I’ll re-awaken my K0 which I haven’t ridden since I rebuilt the K2 Bitsa engine. In the meantime I think I’ll start another quick project, a K2 “flip” bike to raise funds for yet another bike I’d like to buy. Does it ever end, this illness? ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline grcamna2

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #597 on: October 30, 2021, 02:51:01 PM »
Thanks Bill, well nothing much is happening mate as parts are still on their way, I did receive some rear footpegs, a sidecover badge, headlight mounting rubbers and new fuel line on Friday so I’ll install them in the next few days, but the next big thing will be when the engine cases arrive along with the kick starter parts.

We have a long weekend this weekend, 4 days off. It pissed down rain yesterday, the tail end of a massive storm on Friday that ripped out trees, took the roofs of lots of houses etc. one poor guy being interviewed on TV pointed out that in the last 2 years we’ve had devastating bushfires, floods, a pandemic, an earthquake and now this, what’s coming next?

Anyway the storm has fcuked off and the weather should be fine until Tuesday so today I’m taking my 2300cc Triumph for a 100+ miler to scrub in the new tyres I put on it in March or April, then tomorrow or Tuesday I’ll re-awaken my K0 which I haven’t ridden since I rebuilt the K2 Bitsa engine. In the meantime I think I’ll start another quick project, a K2 “flip” bike to raise funds for yet another bike I’d like to buy. Does it ever end, this illness? ;D

Terry,that storm is serious stuff !  I imagine you're pleased you cut some of the trees back a bit when you were up on your roof a little while back.
Will you be switching everything over inside you're present T500 motor to the new-to-you black painted cases so that your engine number is closer to the frame number on this bike ?
Will you save these vapor blasted/present cases for your other build?
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline Terry in Australia

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #598 on: October 30, 2021, 03:29:27 PM »
Thanks Bill, yep once the black cases arrive I'll take them over to Hussein's place to get blasted. He also wants me to rebuild his C92 Benly engine, so I'll probably take his engine home when I drop the T500 cases off, strip the Honda engine, and take him back the cases to blast before I reassemble it with new pistons, rings, gaskets etc.

Once I get my T500 cases back from him I'll swap the guts across. I don't have to do the oil dam mod because the 1974 cases were a new casting with a higher wall to stop the 4th and 5th gear eating issues of the earlier bikes. I'll keep my 1971 cases for the "special" I'm thinking of building.

I am really happy to have a set of cases so close to my frame number, I'm gonna get a custom made frame tag made now with the new numbers. ;D

T500 frame tag by Terry Prendergast, on Flickr
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline grcamna2

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Re: Terry's Boneyard Barn find Budget Suzuki T500 Reanimation.
« Reply #599 on: October 31, 2021, 08:56:20 AM »
Thanks Bill, yep once the black cases arrive I'll take them over to Hussein's place to get blasted. He also wants me to rebuild his C92 Benly engine, so I'll probably take his engine home when I drop the T500 cases off, strip the Honda engine, and take him back the cases to blast before I reassemble it with new pistons, rings, gaskets etc.

Once I get my T500 cases back from him I'll swap the guts across. I don't have to do the oil dam mod because the 1974 cases were a new casting with a higher wall to stop the 4th and 5th gear eating issues of the earlier bikes. I'll keep my 1971 cases for the "special" I'm thinking of building.

I am really happy to have a set of cases so close to my frame number, I'm gonna get a custom made frame tag made now with the new numbers. ;D

T500 frame tag by Terry Prendergast, on Flickr

Terry,Those black cases:that was an excellent thing to find with the numbers so close to your frame number  ;)
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.