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1976 Suzuki GT500
A GT B I picked up locally, I'll do a neat and tidy rider, no chroming, who can afford that anymore.
Pictures will tell the story, some dialogue between pictures.

See my email right at bottom of this page,
contact me with any questions or enquires.
Bike is located in Brisbane QLD Australia.

What's been done: All black steel powdercoated including headlight bucket and ears.
New paint and seat cover, all new badges, new fork seals,
new wheel bearings and sprocket holder bearing and seal, New chain, sprockets and tyres,
spokes replated and reused, new kit in master cylinder, new seal and piston in calliper,
new tacho, speedo cables, new tail light lens, new zinc to all threads.

Motor: all alloy cases, heads, barrels and carbs vapor blasted, crank has new rods, bearings and seals,
top end has new pistons, rings and pins, pistons are +2mm making it 521cc.

Chrome parts are original, cleaned up and present well but not concours.

GT500 suzuki

As found, it did come with the tank and seat
and a spare complete T500 motor that I can use the barrels and heads.

Suzuki GT500

First job, wash it, I like to start clean.

Suzuki GT500

Not too shabby, a nice start, the strip down begins.
Below now are pics not necessarily in any particular order.

Suzuki GT500

So start with the motor, overall look after cleaning was good,
crank moved freely although it was going to be fully rebuilt anyway
I also tested for spark at this time and it was found to be working.

Suzuki GT500

As Ringo says, it don't come easy, it took some.

Suzuki GT500

However stator found to have a bad lighting coil.

Suzuki GT500

A new one was sourced costing $143, wow.

suzuki GT500

So motor fully stripped and cases vapor blasted.

suzuki GT500

This motor already for 1400cc of oil
but I measured it up if someone wants to modify their 1200cc motor,
just build the wall up to 10mm below the kick shaft clamp screw.

suzuki GT500

Crank with new bearings, seals and rods.

suzuki GT500

So there was an issue with Cruizinimage parts,
the seals were loose in the bearings
so my guy made up some sleeves and sourced different seals.

gt500 suzuki

This area was not machined correctly for seal tight fit.

gt500 suzuki

A closer look at the made up sleeve.

suzuki gt500

Time to remember what goes where,
yep I remembered :)

suzuki gt500

suzuki gt500

All the threads nicely re zinc plated.

gt500 suzuki

Bottom end now buttoned up.

Oil pump fitted but I did not end up
using the plastic line cover as I learned the GT never used one
although the mount threads are there for one.

suzuki gt500

So I used the heads and barrels from the spare T500 motor.
now nicley vapor blasted.

gt500

Carbs prepared for cleaning.

gt500

Also vapor blasted

gt500

gt500

Yummy :)

gt500

gt500

gt500

Frame now nicely powder coated
New swingarm bushes used
New bearings (balls) in the triple tree.

gt500

More alloy bits vapor blasted.

gt500

Start polishing and add new decals

gt500

Fork lowers were vapored and I clear coated
Of course new seals were used.

gt500

Gloss caliper paint was used for the disc center.

gt500

Guards cleaned up and under painted with epoxy silver

gt500

Hubs polished and new bearings fitted

gt500

Spokes were replated and reused.

gt500

Caliper paint used, all new internals used

gt500

New plated mount bolts

gt500

New cover for the seat,
the under was treated to new epoxy black gloss paint.

gt500

New tail light lens, yes that was the cost.

gt500

Instruments overall were pretty fair
So I stripped, painted the outer and replace bulbs and painted the mount bracket.

Suzuki GT500

After many many hours we are now rolling.
If you need to know anything more about this build up to this point
email me, see link at bottom of page,

gt500

Top end got nice new pistons, these are +2mm overs.

gt500

About 2/3rds there now and getting into harness work.

gt500

Some pretty paint

gt500

About 90% done here, fiddly bits to go,
more pictures soon.

Suzuki GT500

15/12/2020, first test ride successful,
I'll finish this page with a number of finished images soon.

If you need work done on your classic machine, from basic service to full rebuilds, contact me, I can help.

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