Hey folks new member here would like some help! (gt500)

Bikegeezer · Posted: Thu Oct 08, 2009 7:54 pm Post subject:

There aren't any points. It's a PEI system, and it doesn't need a battery to run the ignition. If it were me, I'd forget about trying to run the motor without an exhaust system. A two stroke won't run worth a crap without the exhaust, and you could burn a piston. Get a hold of a friend who knows two strokes, and pressure test the crank chambers. If it needs crank seals, now's the time to find out. You said you don't know about two strokes, so I thought I'd tell you that bad crank seals don't just cause a mess like a 4 stroke. They can cause the engine to suck the tranny dry or suck air on the left side and either sieze or hole the piston. The fact that it only has 10,000 kilos on it doesn't mean a thing. Time, non-use, and exposure to the elements do the damage.

Stu

04Gixxer · Posted: Fri Oct 09, 2009 2:49 pm Post subject:

Should I just say screw it and not even bother trying to run the motor just yet? Just replace the crank seals anyways? I'll do the piston rings at the same time and what else should I do while it's apart? Then get er back together and go from there?

04Gixxer · Posted: Sun Oct 11, 2009 9:44 pm Post subject:

anyone have a manual for this bike? I want to start tearing down the motor. I know I have my work cut out but I would like to get this bike done by spring..

Bikegeezer · Posted: Mon Oct 12, 2009 3:25 am Post subject:

If you're restoring it, then no - don't bother running the engine. I guarantee you this old 2 stroke needs the full treatment. First thing I'd recommend is to go here Muzza's site and buy this CD. Best money you'll spend on your resto. Here's a page for Suzuki service bulletins - T and GT service bulletins

Familiarize yourself with the bike, and read the engine section before tearing into it. Take plenty of digital pics as you tear it down to help later during assembly. You can't take too many pics. Send the crank to Bill Bune along with a set of crank seals and bearing O rings if he doesn't have a set. The right seal is discontinued in the US, but you can get them from Robinson's Foundry in the UK. BTW, the flywheel is a taper fit on the left end of the crank. Use only a three legged puller - not a claw puller. And don't smack the flywheel with a hammer trying to loosen it. Not wanting to sound arrogant. But there are plenty of ways guys louse up these motors if they aren't familiar with them.

Stu

04Gixxer · Posted: Mon Oct 12, 2009 8:09 am Post subject:

Well thanks for the info but it doesn't seem very economical for me to send a crank that weighs however much across the border to Minnesota all the way from Eastern New Brunswick (Canada). I'm doing this rebuild in memory of a friend that was killed in January so I want to do it all myself. If I can install a new clutch, fork seals, and all the other work I've done to a much more complicated EFI 1 litre superbike I should be able to do the work on this myself don't ya think? Laughing

dorT500 · Posted: Mon Oct 12, 2009 8:56 am Post subject:

You have to split the crank to replace the center bearing seals and two of the four 'O' rings.... The outboard seals are no big deal. Are you set up to do this and press it back together? I think the labor from Bill Bune is only around $125.00 ...maybe a little more since the last time I checked. The crank weighs around 26 lbs. packaged I believe. Packed in foam and in a $10.00 plastic tool box inside a shipping box would be a good way to send it should you decide to go this route.

dorT500 · Posted: Mon Oct 12, 2009 9:20 am Post subject:

A little preview of the lower end.....very simple...it is the crank that you should send off or at least have a two stroke machinist in your area look at. Aside from witness marks he could use...there are dimensions and procedures for crank splitting available somewhere in the links that have been given to you.

imsneeky · Posted: Wed Oct 21, 2009 7:46 pm Post subject:

Just something to think about gixxer. When I bought my gt500, the fellow I bought it from said the crank seals are somewhat fragile if the machine has been sitting awhile.(they dry out). Don't know if this is a concern to you or not. good luck with your purchase/rebuild.

Bikegeezer · Posted: Thu Oct 22, 2009 7:02 am Post subject: