1979 Suzuki X5 Long term rebuild [Archive] - SV650.org

View Full Version : 1979 Suzuki X5 Long term rebuild

mister c

27-12-18, 05:14 PM

Hi.
I seemed to have put my rebuild in the wrong part of the forum. If you would like to see how this started, the thread is here https://forums.sv650.org/showthread.php?t=231180

So, with Christmas upon us, progress has been slow. New tyres were fitted & not a lot else has happened. I've ordered some new parts & even found a couple of impossible to find bits in Indonesia of all places :cool:.
The 1st impossible piece is the handlebar cover. This is a small piece of plastic with "Suzuki" embossed on it. Sat on Ebay at stupid o'clock in the morning & came across this part after hours of trawling.
https://scontent-lht6-1.xx.fbcdn.net/v/t1.0-9/48362184_10218283726304012_1506683198975770624_n.j pg?_nc_cat=103&_nc_ht=scontent-lht6-1.xx&oh=44bc26f295b60d8237205293ce0f7a08&oe=5C916A6D

The Suzuki part isn't painted on the X5, so I took some very fine wire wool & sanded it all off. I then had to make a bracket out of some aluminium plate I have in the shed & fitted it. I'm really pleased as it looks OE.
https://scontent-lht6-1.xx.fbcdn.net/v/t1.0-9/48366939_10218283726824025_7579067339706990592_n.j pg?_nc_cat=107&_nc_ht=scontent-lht6-1.xx&oh=9dade4e0f9a82af40a6bbeaa2b385259&oe=5CCF1862

I also noticed that when the tyres were fitted, the shocks looked wrong. I was correct, when I measured them, they were 280mm centre to centre, X5 shocks are 300mm. I found a compnay called TEC, their shocks look just like standard & were a great price too. They arrived within a couple of days & were really easy to fit. They have made one heck of a difference.
https://scontent-lht6-1.xx.fbcdn.net/v/t1.0-9/48333239_10218265137559305_1991665369827246080_n.j pg?_nc_cat=108&_nc_ht=scontent-lht6-1.xx&oh=0e86a0b484a94f385235dc840658f764&oe=5CCD799C

I've also found a brand new old stock chain cover from the same place in Indonesia & a brand new tail piece cover from a seller in the UK, but waiting for these to arrive.

Today I had some indicators & the front mudguard arrive, so, after work set to in the shed to fit them. The indicators were nice & easy to fit, but the pattern mudguard was a different story. I've had to drill the mounting holes, so used the original as a template. When I drilled the holes & mounted it. Unfortunately, it's sitting a little high, so, tomorrow after work, I'll do some jigging & filing to get it sitting right.
https://scontent-lht6-1.xx.fbcdn.net/v/t1.0-9/49144936_10218367428396512_609375152571940864_o.jp g?_nc_cat=109&_nc_ht=scontent-lht6-1.xx&oh=7b244988f07b67d0818ded7eb5f0e1ea&oe=5CD0C187

Hopefully I should have a few more parts turning up over the next few days.

garynortheast

27-12-18, 06:01 PM

This is really coming together nicely now Col. It looks so close to being there.

Craig380

27-12-18, 08:33 PM

It's looking great! I have a memory that the plastic handlebar trim on my old X5 had the lettering picked out in silver, but that may not be correct.

maviczap

27-12-18, 08:34 PM

A labour of love there Col, especially sourcing those difficult parts

Sir Trev

27-12-18, 09:38 PM

Col - you're quite the magician my friend. Wish I had the patience to do something like this.

mister c

28-12-18, 05:07 AM

This is really coming together nicely now Col. It looks so close to being there.
Still a fair way to go yet Gary. I'm thinking of removing the engine again as the middle crank bearing is a little noisy, I can't make my mind up as I won't be riding it that often

It's looking great! I have a memory that the plastic handlebar trim on my old X5 had the lettering picked out in silver, but that may not be correct.
I'll be honest I can't remember on my original one, but all of the pictures I've seen, they are black

A labour of love there Col, especially sourcing those difficult parts
I think that sourcing parts is one of the fun parts of the build, it takes a while, but you feel quite accomplished when you find them :)

Col - you're quite the magician my friend. Wish I had the patience to do something like this.
It takes my mind away from reality Trev, plus, I should have a nice bike when it's all done :)

Bibio

28-12-18, 11:43 AM

looking superb :-)

mister c

28-12-18, 05:08 PM

Came home from work today & found that another couple of items had dropped through the letterbox. The correct kickstart & a pair of fork reflectors, so, after going food shopping with the missus, I headed off into my leaky shed to play.

The kickstart was plug & play, so a quick tap with a mallet & tighten a screw, it's on :)
https://scontent-lht6-1.xx.fbcdn.net/v/t1.0-9/48939795_10218374887222978_8692048238326317056_n.j pg?_nc_cat=108&_nc_ht=scontent-lht6-1.xx&oh=00de680c719641a765b0c0880ed31f19&oe=5CD95E48

Next on the agenda was lowering the front mudguard. It didn't take me too long to re drill 4 holes a little further down the ribs & check to see what it looked like. In my opinion, a lot better. It could go lower still, but I think it looks right now. I took the grinder to the excess webbing & ground it to tidy it up.
https://scontent-lht6-1.xx.fbcdn.net/v/t1.0-9/48982096_10218374887382982_4964016715592630272_o.j pg?_nc_cat=107&_nc_ht=scontent-lht6-1.xx&oh=dadca70db22112a7b855b2c80dc0b2c4&oe=5C8D263F

The last part today were the fork reflectors. I ordered 2 from China for £2.20 delivered. When I opened the packaging, there were 2 PAIRS in the bag. So I had 4 reflectors for £2.20 delivered from China, how on earth is that possible?
I did have a slight problem as the screws on the reflectors were 6mm & the holes in the yoke are 5mm. I took a reflector apart to see how they were made & it had a screw bonded into the plastic. I used my grinder to get rid of the excess plastic, removed the screw & replaced it with a 5mm one. I screwed it into the yoke & replaced the reflector top. It's as good as new :)
https://scontent-lht6-1.xx.fbcdn.net/v/t1.0-9/49181144_10218374887062974_4225409944158994432_n.j pg?_nc_cat=101&_nc_ht=scontent-lht6-1.xx&oh=5de9f6d52f50897b98822ddc0cf949b0&oe=5CCE6D16

garynortheast

28-12-18, 07:10 PM

I assume the hole in the mudguard is for a speedo cable guide/fixing?

mister c

29-12-18, 08:25 AM

I assume the hole in the mudguard is for a speedo cable guide/fixing?
It is mate, yes

mister c

30-12-18, 12:44 PM

Just goes to show that you should never throw stuff away. Front brake line off an SV that I had lying around in the dark recesses of my shed. Hey presto, it fits perfectly. A nice little saving of £40

https://scontent-lht6-1.xx.fbcdn.net/v/t1.0-9/49450565_10218382443011868_4412689897157033984_n.j pg?_nc_cat=108&_nc_eui2=AeFaHa5Fd8R-PAhOYwtLX6vb4I2UjS4pCT7iQp8S0pXeOEz12F9dCqNErly-twrlDRmuRsqaDu1tywIHVSJ4EsR1q2XW54_tWgwJLzPum84K0w&_nc_ht=scontent-lht6-1.xx&oh=6449e4632642de8b90d46daa94ba5967&oe=5C8C1946

mister c

01-01-19, 08:42 AM

My NOS chain guard arrived from Indonesia yesterday, brilliant service saying that it was only ordered on Christmas Eve. Only 2 screws to fit, so took no time at all.
https://scontent-lht6-1.xx.fbcdn.net/v/t1.0-9/49067493_10218397599670775_8865748187634204672_o.j pg?_nc_cat=100&_nc_ht=scontent-lht6-1.xx&oh=dc77016392278536b7f27f6b2b37a164&oe=5C8ECCD6

I'm keeping a tally on how much it's cost in parts & today it's topped £2000. I'm amazed saying that in 1979 I paid less than £700 for a brand new one.

Craig380

01-01-19, 09:23 AM

Heh, in early 1982 my V-reg (1980) X5 was £299 from a dealer, with a Haynes manual thrown in :)

mister c

01-01-19, 09:59 AM

Heh, in early 1982 my V-reg (1980) X5 was £299 from a dealer, with a Haynes manual thrown in :)
:smt119:smt120:smt088

maviczap

01-01-19, 02:39 PM

Heh, in early 1982 my V-reg (1980) X5 was £299 from a dealer, with a Haynes manual thrown in :)

Aye, but them's thare days when you could go out of a night with a fiver, drink all night & still 'ave change for chips on the way home, thay knows :p

Craig380

01-01-19, 04:50 PM

Aye, but them's thare days when you could go out of a night with a fiver, drink all night & still 'ave change for chips on the way home, thay knows :p

Well, I remember well that in 1981 a pint of Stella (which was posh lager back then :smt082) was 65p ...

mister c

03-01-19, 08:03 PM

I spotted the holy grail of parts on Ebay on Christmas Day, so bought it straight away. This little lid is new/old stock again, but has to be the rarest part on an X5. I have been offered £100 for my 2nd hand one with holes in, so that has now been sold. It's a shame that my bikes going to be blue really.
https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/49487646_10218422316608683_8910818715444969472_n.j pg?_nc_cat=102&_nc_ht=scontent-lhr3-1.xx&oh=11c054a792e76eb5e7c42c597e305c4c&oe=5CBFE4D3

mister c

13-01-19, 01:16 PM

I've decided that I need to get a life. Following on from the new tail lid, I've sold my old one for a nice profit, bought another 2nd hand one & sold the "new" old one for a tidy profit, which should pay for my paint, so a nice bonus for being a Billy No Mates that sits on Ebay all of the time :)
Anyway, on with the plot. I have bought another shed load of bits & am not far off completion. We now have mirrors screwed onto the handlebars, new bulbs in all the right orifices, a chain & sprocket kit fitted, spark plugs & caps in the motor & rubber mounts on the side panels. I plugged all of the electrics in & found that the fuse kept blowing, so I fitted a slightly larger fuse & the regulator rectifier decided to sizzle & go up in a puff of smoke before blowing the fuse again :(
Electrex do a new regulator for £12, so will call them tomorrow which will hopefully sort out the problem. All I'm waiting for now are the rear brake switch, a couple of nuts & bolts & then some paint, which I'm going to get tomorrow too from BS Supplies in Stoke. This time I'm staying away from rattle cans & heading over to a friend of mine that has a decent spray gun & huge garage for me to prep & spray it properly, so watch this space! My mate is a proper stickler for perfection, so it should be right when it's done.
https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/49721826_10218471347234418_8964056415626854400_n.j pg?_nc_cat=109&_nc_eui2=AeFitkvEjRnMJ25EUsE_RONHdaCOSysq36aWUmhkU Uf06z0vdeEzj8ZP8lgv1_LIE0v17v8e-f08RIrewyjXFaMEPd1OWRSpo1kGN3xUHWOwjQ&_nc_ht=scontent-lhr3-1.xx&oh=03261088aa4d517346d7e2daa3298c47&oe=5CB89096

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/49914620_10218471347674429_5012308417335787520_n.j pg?_nc_cat=111&_nc_eui2=AeG1aK9w5V1JKXxVR202X3TrSzNjE-2NGK1uMjOhOt6-z2YwVWC_NRV6R9Gr8pKR9oJ5HBoSgmXeaqnoS5hEtcuxBTNP0x AcExYHfDWrLJDXHg&_nc_ht=scontent-lhr3-1.xx&oh=632632d1565f0e18a8102ef014d4ac8b&oe=5CD49EF7

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/49848387_10218471348594452_2608678816792444928_n.j pg?_nc_cat=102&_nc_eui2=AeGj9yyy5Ywt7D4SWtKQ7SrBFsHRc3TvejaHpW2oS UmCVbGKo2WA1ab5VsvzSBjWHT9XXw_bGC3eYpnVWPHs6nE6T3o VVTCjMRZ_PgYet_JnUw&_nc_ht=scontent-lhr3-1.xx&oh=c8fcafad81b895057bb2e944c4bcc447&oe=5CD4790C

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/49764868_10218471348994462_6351434432309624832_n.j pg?_nc_cat=100&_nc_eui2=AeFwFB7daW1oF8SIw_Ei_tWdSS8cFRlQcPN78zh0W rFTC3EeseANa893N36IJbVReO7JCIdIjsxCNZ7DGs6mgspD_9G d1uQ3xcKLhIqqB-4q2g&_nc_ht=scontent-lhr3-1.xx&oh=8f98fa2f99af969792d9c279f6e0c271&oe=5CCF0D8F

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/49682662_10218478855062109_490857475659005952_n.jp g?_nc_cat=101&_nc_eui2=AeH2XdF_oN3r31JvNDwuOVEcVyqOopy1J6jvbPjSj NUUJqEivF-e5U_nV5cZPWJUHN280Dn-gcw4Iz6kGhOa4lscyugjPSaDlBDhcLFTlIpoFg&_nc_ht=scontent-lhr3-1.xx&oh=2ce86e2717ed8e47cda227e379d45ac9&oe=5CCF9159

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/49707204_10218478854022083_578683844555702272_n.jp g?_nc_cat=106&_nc_eui2=AeF1oyb_bQdvPWhnz3CQ4rBxaEmz5mZkbUzuv6RGq-m69ZY_Z5eurMDSutTxok9izoiiWvhS0gC7yCTbg89ISMI0iUfe kQ5NOv79u58xMIpsww&_nc_ht=scontent-lhr3-1.xx&oh=c0ae115f0edb2f2412b4369e8987add3&oe=5CC375B1

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/49661542_10218478854422093_3327490955837177856_n.j pg?_nc_cat=105&_nc_eui2=AeGLLPNYCB5E3-GuL7ro1WTXOHn8c5_dvn987ekEJlC4FM1RTHTMrXfPJayep8bE v3PrqAF1ECtw4K1QB99nhYIJ_Y5ba17GW4rAy1iOlecaVQ&_nc_ht=scontent-lhr3-1.xx&oh=9f8095ec33553414fa21c32dc3ce44aa&oe=5CD33F7E

Sir Trev

13-01-19, 02:40 PM

That is already so cool - when it's finished and riding down the road it's going to be epic as I'm sure it will look mint based on your last few builds.

garynortheast

13-01-19, 04:57 PM

Whoah, this is getting exciting now! Can't wait to see this!

Adam Ef

22-01-19, 07:56 PM

Someone's put a very nice condition one up for sale on FB today...
https://www.facebook.com/marketplace/item/374615146698413

mister c

23-01-19, 07:11 AM

Someone's put a very nice condition one up for sale on FB today...
https://www.facebook.com/marketplace/item/374615146698413
Not a bad price. I've spent well over £2000 on spares alone. That one needs some work to make her look original, but I would say it's worth the money

Craig380

23-01-19, 07:49 AM

mister c

02-03-19, 07:55 AM

Don't do what I did over the weekend and browse through back-issues of Classic Mechanics from 2012 / 2013. Classic strokers were dirt cheap compared to now. An RD200 in decent condition with current MOT etc for £800 ono!
It breaks my heart sometimes to think of some of the bikes I've had in the past 7 how cheap I sold them for.
So, a little update. I've been having electrical problems with the little 200, which i think I may have found. The electric start spring was staying connected when the engine was running & burned out 2 Reg/Recs :(. I've ripped the wiring out & will be performing a little surgery on a couple of broken wires too.
On a plus point, she now has a new seat cover, which I'm not too pleased with, so have ordered another to get it right & stainless steel clutch & brake bolts. I've also glass fibred the broken seat cowl & have my decal set ready for when it eventually gets painted. Money is a little tight at the mo, so play has stopped for the time being. I did solve a little problem with the bike's running, I'd fitted 2 left hand slides in the carbs, so that's now sorted & she runs sweet.
XzbYeJeCgt4

https://scontent-lht6-1.xx.fbcdn.net/v/t1.0-9/49848584_10218507743104292_2001138993940398080_n.j pg?_nc_cat=101&_nc_ht=scontent-lht6-1.xx&oh=e1ed7c34c94b6a1f147c9311695b6124&oe=5D20E030

https://scontent-lht6-1.xx.fbcdn.net/v/t1.0-9/49898523_10218514332309018_8342246993430577152_n.j pg?_nc_cat=109&_nc_ht=scontent-lht6-1.xx&oh=35db147b9b220026b3551eb518313641&oe=5D2024A5

https://scontent-lht6-1.xx.fbcdn.net/v/t1.0-9/50083632_10218514818641176_5282186539965612032_o.j pg?_nc_cat=106&_nc_ht=scontent-lht6-1.xx&oh=fb6d04e237f528b9a8b1f5ee0abb3026&oe=5D17B9B5

https://scontent-lht6-1.xx.fbcdn.net/v/t1.0-9/50442128_10218550152284495_6219913054713282560_o.j pg?_nc_cat=104&_nc_ht=scontent-lht6-1.xx&oh=d1f4732e94f0565d506bce8192051245&oe=5CE893CB

Othen

10-03-19, 07:35 AM

It breaks my heart sometimes to think of some of the bikes I've had in the past 7 how cheap I sold them for.
So, a little update. I've been having electrical problems with the little 200, which i think I may have found. The electric start spring was staying connected when the engine was running & burned out 2 Reg/Recs :(. I've ripped the wiring out & will be performing a little surgery on a couple of broken wires too.
On a plus point, she now has a new seat cover, which I'm not too pleased with, so have ordered another to get it right & stainless steel clutch & brake bolts. I've also glass fibred the broken seat cowl & have my decal set ready for when it eventually gets painted. Money is a little tight at the mo, so play has stopped for the time being. I did solve a little problem with the bike's running, I'd fitted 2 left hand slides in the carbs, so that's now sorted & she runs sweet.

https://scontent-lht6-1.xx.fbcdn.net/v/t1.0-9/50442128_10218550152284495_6219913054713282560_o.j pg?_nc_cat=104&_nc_ht=scontent-lht6-1.xx&oh=d1f4732e94f0565d506bce8192051245&oe=5CE893CB

That is quite incredible, your attention to detail is phenomonal.

I have a feeling you would simple hate the oily rag renovation of my 1976 Bloop:

https://www.tapatalk.com/groups/ccm_mad/suzuki-b100-t4832.html

Best wishes,

Alan

Craig380

10-03-19, 08:37 AM

Othen

10-03-19, 08:53 AM

The B100P looks good! You've saved it and got it running again, that's the important thing. I passed my bike test in 1981 on an identical model (even the same colour).

I think I only ever saw 65 on the clock once, on the legendary Beeford straight in East Yorkshire (on the A1079 to Bridlington) so if you can see 60 on the speedo, it's fine ;):D They never had much power, and the delivery is like an MZ, just rev it through the gears until it goes flat then change up. As mentioned elsewhere, abusing the silencer with mallets, plumber's tubing and old bowden cables fixed in a drill chuck will ensure it's giving all of its mighty 10 (claimed) BHP.

Thank you for that Craig. I never rode a Bloop back in the day, so it is helpful to know that 65 MPH was about the maximum speed. The other factor is that I’m 6’2” and 90KG - which probably accounts for the missing 5 MPH!

I’m pretty pleased with the Bloop, it was far too good to scrap and is saved. I even like the oily rag finish and don’t mind the little faults it has (like the pilot jet screw, the little cover over the carburettor missing and the pop riveted plate over the hole in the black painted muffler). In many ways those little foibles add to rather than detract from the bike - it is like someone’s dad just parked it outside after commuting to his job at the shoe factory in Kettering and left it there. It even has a 1986 tax disk on it in the original (rusty) holder.

Alan

Sent from my iPad using Tapatalk

R1ffR4ff

10-03-19, 10:01 AM

).

I think I only ever saw 65 on the clock once, on the legendary Beeford straight in East Yorkshire (on the A1079 to Bridlington) so if you can see 60 on the speedo, it's fine ;):D .

Ah the old,"Beeford Straight".I still ride it on my SV but it always takes me back my youth when I used ride to,"Brid" on my Norton Dommie 88/ 500 :thumleft:

PS
Lovely work on the bike :)

Craig380

10-03-19, 12:42 PM

Thank you for that Craig. I never rode a Bloop back in the day, so it is helpful to know that 65 MPH was about the maximum speed. The other factor is that I’m 6’2” and 90KG - which probably accounts for the missing 5 MPH!

It's worth noting that 65mph on the clock was achieved in the following conditions:
- rider aged 17, weighing 10 stone
- feet on pillion pegs, chin on tank, left hand on fork leg for that 'flat tracker' style
- 1 mile run-up along the straight, with a mild tailwind

Ah, youth :thumright:

Ah the old,"Beeford Straight".I still ride it on my SV but it always takes me back my youth when I used ride to,"Brid" on my Norton Dommie 88/ 500 :thumleft:

It was THE top-speed testing ground in the late 70s / early 80. Well, during the daytime, anyway. There was a well-known case in the early 80s of a biker hitting a stray cow while giving it the beans along the straight at night :(

Othen

10-03-19, 12:51 PM

It's worth noting that 65mph on the clock was achieved in the following conditions:

- rider aged 17, weighing 10 stone

- feet on pillion pegs, chin on tank, left hand on fork leg for that 'flat tracker' style

- 1 mile run-up along the straight, with a mild tailwind

It was THE top-speed testing ground in the late 70s / early 80. Well, during the daytime, anyway. There was a well-known case in the early 80s of a biker hitting a stray cow while giving it the beans along the straight at night :(

I thought that might be the case, in which case aiming for 60 MPH with a 6’2” 15 stone rider sitting bolt upright and wearing a puffa jacket sounds quite reasonable. If we get a nice day this week I’ll take the Bloop out to try it.

Sent from my iPad using Tapatalk

Othen

10-03-19, 02:17 PM

The weather improved a bit so I took the Bloop out for a test ride - and hit an indicated 60 MPH on a slightly downhill stretch - so the rings have worked. It still ran out of puff slightly at the top end, so either the ignition needs advancing slightly, or the main jet needs cleaning - or the muffler has a bucketful of carbon in it (... or several of the above).
I’m pleased with it though.

Sent from my iPad using Tapatalk

R1ffR4ff

10-03-19, 02:21 PM

mister c

11-03-19, 08:26 AM

That is quite incredible, your attention to detail is phenomonal.

I have a feeling you would simple hate the oily rag renovation of my 1976 Bloop:

https://www.tapatalk.com/groups/ccm_mad/suzuki-b100-t4832.html

Best wishes,

Alan
The BlOOP has been saved, which is good & it's nice to see that you're going to keep it, it's another classic that isn't destined for the scrapyard :)

The X5 was going to be a full restoration as I owned one in 1979 (It was my 1st ever motorbike).
The main problem has been the price of parts, they were only built for a handful of years, so parts command a high price (when you can find them). I have a pair of std silencers, but the chrome platers wanted over £350 for the pair & the Gibsons turned up at over £100 cheaper :) I'd always wanted expansion pipes when I was a youngster, so couldn't say no

Othen

11-03-19, 09:14 AM

The BlOOP has been saved, which is good & it's nice to see that you're going to keep it, it's another classic that isn't destined for the scrapyard :)

The X5 was going to be a full restoration as I owned one in 1979 (It was my 1st ever motorbike).
The main problem has been the price of parts, they were only built for a handful of years, so parts command a high price (when you can find them). I have a pair of std silencers, but the chrome platers wanted over £350 for the pair & the Gibsons turned up at over £100 cheaper :) I'd always wanted expansion pipes when I was a youngster, so couldn't say no

I’m not sure many would see the Bloop as a classic, but it is a cute little bike that was too good to break, so I take your point.

What you have done with the expansion chambers is perfectly acceptable - that is a sensible modification that many would have done if they could have afforded to do so back in the day.

You did well with the X5 - not many would have had your attention to detail (including me - I’d have just got it running and riding - an oily rag restoration).

Alan

Sent from my iPad using Tapatalk

mister c

09-04-19, 02:41 PM

Well, it's been a while since I've done anything on the X5, so thought I would pop outside today to see if I can find my mojo to get it done. I failed, but did have a quick ride on it to check the gears selected ok :)

EET82XjBnfQ

Craig380

09-04-19, 03:43 PM

Ooooh, it sounds SO good :)

Othen

09-04-19, 03:59 PM

It is the 70s again!

Sent from my iPad using Tapatalk

Sir Trev

09-04-19, 06:54 PM

Mmmmmmm..... Two stroke exhausts. Part of me misses them quite a lot.

Craig380

09-04-19, 07:13 PM

Mmmmmmm..... Two stroke exhausts. Part of me misses them quite a lot.

A few years back, when I still had my 380 with J&R Power Pipes, I pulled up at some traffic lights and a rider who I'd noticed following me for a few miles pulled alongside on a modern adventure bike. He shouted across: "I couldn't overtake you, I was enjoying listening to it too much ..." :D

garynortheast

09-04-19, 09:22 PM

Sounding good Col.

mikerj

11-04-19, 08:02 PM

Great thread! Not been on the org in quite a while so missed this.

I bought an X5 for £30 a bike breakers whilst I was doing my A levels about 30 years ago (bloody hell, really that long? :() with loads of bits missing and a dead ignition. I rewound the ignition stator and eventually scraped together enough s/h bits to get it back on the road and used it for several years, regularly racing around Dartmoor with my mate who had a GT185. I still have that bike, though it is literally buried in the back of my dads garage to the extent that I haven't seen it for about 20 years.

I also have a B120 which is ready to be reassembled after spending a long time sourcing various new old stock parts. Not a bike I particularly wanted, but my dad randomly bought it for me a couple of years back as I used to have a B100P I rode around my gradparents farm when I was 11-12 years old, and thought I'd like the nostalgia. Unfortunately it was the most rotten, nastiest example I've ever seen; even the swing arm was rotted out. Spent way more than it's worth on it because I'm daft.

mister c

23-06-19, 05:32 AM

Again, it's been a while, but here's an update. My mojo for the X5 & anything bike related has been out of the window of late, but decided to get my backside into gear a couple of weeks ago & source some paint.
BS Supplies in Stoke on Trent are a brilliant company to deal with, they are so helpful in anything paint related, I've always used them for my rattle cans.
This time however, I was venturing into the world of spray guns, thinners, hardener & paint. I was going to get my mate to spray the panels for me, but decided to have a bash myself as you can always sand it down & do it again. I have a small, cheap compressor & an even cheaper spray gun which came in the obligatory free tools kit that came with it, so went to B. S. with an old panel for the paint match. It was all sorted within about 20 minutes, the assistant told me how to go about mixing 2 pack & that if I had any problems, give Matt a ring as he's a whizz kid on anything spray related.
So, the hard work started with removing old decals & paint (This is where the Wife's hair drier came i very handy :) )
https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/64225600_10219690414390335_3717155866676297728_n.j pg?_nc_cat=109&_nc_oc=AQnLwU3PRorys90LTuxeTmaUph2wd1qxxpwI-hj-ApJUkrexTjpg0X_B7GRCxWS0xl8&_nc_ht=scontent-lhr3-1.xx&oh=773d9a31dfd24cc9bd28e31d987c2b10&oe=5DC129AA

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/62651313_10219690414230331_8695491595211898880_n.j pg?_nc_cat=106&_nc_oc=AQnjktpts3Y6oLqWvBphEUdUexABAkOLM53jVt8DQ3y EZtjaAQ4PR1WHzYHaeEcOHD8&_nc_ht=scontent-lhr3-1.xx&oh=95367fd2a8734d7ccf4089e99e8ea938&oe=5DC4A066

So, with it all de stickered, the hard graft of sanding, smoothing, priming & generally tidying up the surfaces ready for the top coat.
https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/64640817_10219690412950299_282478289660936192_n.jp g?_nc_cat=103&_nc_oc=AQnR4oB05UIU2OAb_0Cx914rmIXKJUyenWFEy04kJCu cTTwZpH6pWAvnv6j0Sa3Sgok&_nc_ht=scontent-lhr3-1.xx&oh=7a59413ffeed03b1ccc561ce0de9c7ce&oe=5D7EF05B

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/62396927_10219690413950324_2368585905813323776_n.j pg?_nc_cat=106&_nc_oc=AQkDiPZuKtDy-3xgRtcO7XeP8Ej-QKk1Zd2PL7TUZPUyxTaZfFcJlQ2EqwBusBHudqQ&_nc_ht=scontent-lhr3-1.xx&oh=3042f53cd5140c575cfb976930957b1f&oe=5D7E356E

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/64480381_10219690412550289_7948536446736924672_n.j pg?_nc_cat=105&_nc_oc=AQkNHBta9610ED2LlU6nxXi1KvAe6krOTtRO5F95erd RWevdXutEgDQNHaz_XswzMmY&_nc_ht=scontent-lhr3-1.xx&oh=04a597580256b2210fdedcede049cfd4&oe=5D7B780B

Once I was happy with the primed bodywork I had to wait for a decent day as my shed is like a collander & I also needed some heat to get the paint to harden. I was talking to a friend, who said, "You need to be careful with that 2 pack paint it contains cyanide". Well, that made me start to worry &, reading posts on websites of people having to be resuscitated after using it, I started to panic &started to think about going back to my trusty rattle cans. After more reading &, more importantly, reading on the health & safety website that the paint "had the possibillity" of giving you Asthma & wouldn't kill me, I bit the bullet & set things in motion for the next nice day.
That turned out to be yesterday (Saturday). I woke up very early (4am), took the dog for a walk, had a brew, then waited for a half decent hour to turn my compressor on. I brought the panels into the back yard, hung them on the line, mixed the paint & started to spray away :)

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/65142265_10219739527538133_4273577418268082176_n.j pg?_nc_cat=111&_nc_oc=AQkcE986s1z5QW5zpZZBg9c0jO_Mc3cWnyi2Ro5fw4i nu1yXRfJMpX6KzILppGpoR3w&_nc_ht=scontent-lhr3-1.xx&oh=895772aeef593a4b9d0223e32b81b492&oe=5D899719

"Hmmm, this 2 pack paint is rather good" I thought, you don't need lacquer once the paint has dried, so once the panels were all painted with about 30 coats I left it to bake in the lovely sunshine we had.
It was then that disaster struck. The wire holding the tank on the line decided to give up the ghost, the tank fell, hit one of the sidepanels on the way to the floor, then roll across the yard, I was mortified. So, it was out with the sand paper, filler & paint again to cover up the mess :(

Next job was to flat & polish the paintwork. I used 1200 grit sandpaper very lightly across the tank's surface with lots of water, then used a colour restorer as a polish.
https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/65172710_10219739527018120_251996047767764992_n.jp g?_nc_cat=108&_nc_oc=AQnDR3L8TskqFrjEjLJxQ8i84J8025fw_FfCI5NFBuK 5bv2nFNJ71Qd7xps-0wPvxVw&_nc_ht=scontent-lhr3-1.xx&oh=4248f1091e101fb8061de439f34e13a2&oe=5D7EF5EA

After about 3 hours of constant sanding & buffing I ended up with a very shiny tank, it's not perfect as it has some small blemishes, but I am really impressed. The next step were the Decals. I had bought a full set from Retrodecals on the net & hoped that this stage would go ok as they cost a small fortune ( in the great scheme of things), but the quality is top notch & period correct, so I'm not complaining. I had taken measurements of what went where before I stripped the tank, so got my tape measure out, placed masking tape at certain points & put them on. Wow, what a transformation, I can't wait to get the sidepanels & tail piece done now to show off the full bike......... Watch this space......
https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/64688057_10219739529458181_5262592065937604608_n.j pg?_nc_cat=108&_nc_oc=AQnxqJRHoerqgePlzuwDBPcHa7J8qcdsA7LWAH5fYNh OZ-DIGhxgXs9KPNqQmC6Gty4&_nc_ht=scontent-lhr3-1.xx&oh=64f2ea7412f5a1fd3b27720b2a2d4c0d&oe=5D7E0D19

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/64693151_10219739527258126_2973343882642718720_n.j pg?_nc_cat=110&_nc_oc=AQmCJcDDuyhpM7omGUdriYJqLmTjK3nZyexzUpWkxe1 NzM1zzq8ct2fthhwYZJoCGKw&_nc_ht=scontent-lhr3-1.xx&oh=9555c743f9a635ae40c9086f0215e9fc&oe=5DB9EED8

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/64940922_10219739527418130_4226154949186158592_n.j pg?_nc_cat=103&_nc_oc=AQmvHsfFCxNTCQOnqr9WY9QjjPeRvcyOkqg9n9fdf42 H_UIZ1irvdOPUc9vnsks6Jyw&_nc_ht=scontent-lhr3-1.xx&oh=d94179b71931f8ea4c5bf963de50b8ee&oe=5D81AFB3

Othen

23-06-19, 05:42 AM

Well done.
I enjoy reading this thread and I’m very respectful of what you have done with this bike - the paint looks very good indeed. I suspect it makes no financial sense to spend so much on a bike like this, but that is perhaps not the point: you find it satisfying (which I think is the point).

I enjoy restoration projects also, but at the other end of the scale: mine is a Bloop (1976 model) - saved from the breaker’s yard, given an oily rag finish and now going so well it makes me grin every time I ride it:

https://uploads.tapatalk-cdn.com/20190623/95e68a0793842121be568e1055dd50c9.jpg

Good fortune,
Alan

Sent from my iPad using Tapatalk

Craig380

23-06-19, 06:53 AM

Oh man, I can't imagine what it must have felt like when the tank dropped :(

But it now looks MINT, it's exactly the colour mine was. Great job!

Talking Heads

23-06-19, 10:46 AM

X5 was a lovely wee bike, its only flaw was that it wasn't an X7

Talking Heads

23-06-19, 10:48 AM

Othen

23-06-19, 10:55 AM

Completely agree.

Please don't ever restore the Bloop, its perfect just as it is.

... I agree, that was sort of the point of saving it from the scrapper: it has taken 43 years to look this good :-)

Sent from my iPad using Tapatalk

garynortheast

23-06-19, 04:10 PM

That looks absolutely fantastic Col! I think I need to have a spin over to take a look at some point!

SVSte

23-06-19, 04:58 PM

The X5 Looks great I had a X7 back in the day in the same blue, been looking at the thread and the end result is great, there is Nowt wrong with the Bloop a real bike and shows how good Suzuki are at making bikes.

mister c

23-06-19, 05:44 PM

BLOOP is looking goodo, how do these experts put it? "Great patina". :)
I bought an X5 brand new back in 1979, so have wanted one for quite a while. This came up (in boxes) for £350, so had to buy it & restore it back to a good condition while honing my skills learning how to sort things, especially spare parts that are as rare as rocking horse droppings. This one is a keeper & will hardly get ridden at all.
Well, I was awake early again this morning (3:45am) so took the dog for a walk, made a brew & headed off to the shed. The plastic wouldn't shine up as well as the tank so I resorted to fixing the decals, then applying lacquer over the paint to make it shine. The overall effect is really nice, I'm so pleased with it. I now have a long road ahead cleaning her up as she's been in the leaky shed for nearly a year & a half. It will then be a case of number plate, MOT then take her for a little test run

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/65076261_10219744729348175_4386688693428027392_o.j pg?_nc_cat=102&_nc_oc=AQmNB9T1CYtofGnyQLfUCC6LHixS3Mco9JXYPIGmpn_ iY57VA2j9AAL7XWI65nchxaY&_nc_ht=scontent-lhr3-1.xx&oh=4dd0e69de6cc3fa3b67dcfbb9759c08e&oe=5DC44F88

garynortheast

23-06-19, 05:49 PM

Stunning restoration and lovely to see it all together like that.

Othen

23-06-19, 06:10 PM

That is a wonderful bike, you should rightly feel very proud of yourself for turning a box of bits into something quite lovely. Well done, and thank you for posting such an interesting thread for us to enjoy.

The Bloop - yes, I have a soft spot for it and keep taking it on needless errands. This afternoon I took it out for 20 minutes to ‘charge the battery’ :-)

Sent from my iPhone using Tapatalk

mister c

23-06-19, 06:38 PM

Stunning restoration and lovely to see it all together like that.
Cheers Gary. It's not all original, but it looks the part. I would be in the shed polishing now, but it's chucking it down & don't want to get wet.... I really should fix the shed roof
That is a wonderful bike, you should rightly feel very proud of yourself for turning a box of bits into something quite lovely. Well done, and thank you for posting such an interesting thread for us to enjoy.

The Bloop - yes, I have a soft spot for it and keep taking it on needless errands. This afternoon I took it out for 20 minutes to ‘charge the battery’ :-)

Sent from my iPhone using Tapatalk
I'm the same with my SV. I keep threatening to sell it, but haven't got the heart. It's nice to just go for a short bimble every couple of weeks, it keeps us happy :)I am thinking of a chopper, or bobber for the next project, I'll have to see how the funds are

Toooldtodie

30-06-19, 04:11 PM

OMG!
This was my first ever bike. What memories. Mine was yellow and missing the X5 200 decals as I passed it off as a 125 as the new rules on learners came in...
That YouTube clip and the soundtrack took me back 35 years!
Great job on the restoration, mate.

mister c

24-07-19, 05:38 AM

Don't spend too much time on here anymore (should try harder), but Facebook seems to have taken over from forums unfortunately.
So, for those people that I don't have on facebook, here is the X5. She is finished, MOT'd & on the road. The carbs need sorting out as she doesn't run too well at the moment, she bogs down at the bottom end. I've also got an oil leak, I think from the clutch pushrod oilseal, so will sort these little things out at the weekend.
Looking for my next project now, but may be moving home 1st, so will have to wait & see.

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/67402199_10219977432605611_3997286333939712000_o.j pg?_nc_cat=102&_nc_oc=AQliTj_YkKGrp9HoqJowhHx65j6bP64Wp9d2pOsPFxX U9ocAsS-9hezWCSZMr3IVv3Q&_nc_ht=scontent-lhr3-1.xx&oh=3a8bb4515e604de856d5108c61204e66&oe=5DEB4EDB

wifjjWNWwiw

Geodude

24-07-19, 06:23 AM

Cheers for the update Col, and for remembering us non farcebookers too :D Awesome work as usual and look forward to the next episode of 'Mr C makes' :D

garynortheast

24-07-19, 07:10 AM

It's great to see it all finished and on the road Col. If you fancy meeting up for a cuppa at some point somewhere, I'd love to take a ride over to see it.

shiftin_gear98

24-07-19, 07:16 AM

That is lovely looking, enjoy riding it.

Sir Trev

24-07-19, 06:13 PM

Fan-flippin-tastic job there Col. Good to see the plastic covers finally came off the footrest rubbers too :cool:

mister c

26-07-19, 06:28 AM

Othen

26-07-19, 06:54 AM

Thanks for the comments. I think that I'm going to have to rebuild the engine again. I thought that I was lucky that she ran with such an old crankshaft in, but have been having problems with carburation.
The bike ticks over fine & runs great after 6000 rpm, but is really fluffy up to 6k. The only thing I can put it down to is the crankshaft oil seals as I've set the carbs as per the manual, then set them as well as I could to no avail. The way finances are at the moment & with Winter on its way soon, I dont think it will be done until next year :(

What a pity, it is a very nice bike, indeed you have made such a nice job of it that you have to fix it properly.

Have you pressure tested the crankcase yet? You are a very competent mechanic, so I’m guessing you know how. It would not take long to rig up some bungs, a pump and a gauge to check out each side with the bike still in the frame. That won’t help fix the issue, but you will know what and where it is. At the very least you will be able to identify whether the issue is with an outer seal or (I suppose much more likely) an inner seal.

I rather assume you changed the outer seals on both cylinders as you were building up the motor, but depending on the results of the pressure test I wonder whether it might be worth changing both again. I don’t know that particular engine, but it looks like it is piston ported (well, no disc valves anyway) so the outer seals will be a really simple (and cheap) job.

Good fortune.

A

Sent from my iPad using Tapatalk

Craig380

26-07-19, 07:17 AM

Thanks for the comments. I think that I'm going to have to rebuild the engine again. I thought that I was lucky that she ran with such an old crankshaft in, but have been having problems with carburation.
The bike ticks over fine & runs great after 6000 rpm, but is really fluffy up to 6k. The only thing I can put it down to is the crankshaft oil seals as I've set the carbs as per the manual, then set them as well as I could to no avail. The way finances are at the moment & with Winter on its way soon, I dont think it will be done until next year :(

That could be the spannies causing the fluffiness ... it's a sweeping generalisation but if a stroker starts easily from cold and isn't burning gearbox oil, the crank seals are usually fine. And smaller engines will show the effects of slightly off carburation more than a bigger engine.

It's dead easy to raise / lower the needles in those carbs, have you tried moving the needle clip to see if it improves things?

It's also easy to makes a quick test of whether it's rich or lean at mid-range rpm and medium throttle openings - just give it half choke. If it runs with less fluffiness, raise the needle. It it runs worse, lower the needle.

Good luck, I hope you can sort it without having to do open motor surgery.

Dave20046

26-07-19, 10:53 AM

Looks great Mister C!

mister c

27-07-19, 07:28 AM

What a pity, it is a very nice bike, indeed you have made such a nice job of it that you have to fix it properly.

Have you pressure tested the crankcase yet? You are a very competent mechanic, so I’m guessing you know how. It would not take long to rig up some bungs, a pump and a gauge to check out each side with the bike still in the frame. That won’t help fix the issue, but you will know what and where it is. At the very least you will be able to identify whether the issue is with an outer seal or (I suppose much more likely) an inner seal.

I rather assume you changed the outer seals on both cylinders as you were building up the motor, but depending on the results of the pressure test I wonder whether it might be worth changing both again. I don’t know that particular engine, but it looks like it is piston ported (well, no disc valves anyway) so the outer seals will be a really simple (and cheap) job.

Good fortune.

A

Sent from my iPad using Tapatalk

That could be the spannies causing the fluffiness ... it's a sweeping generalisation but if a stroker starts easily from cold and isn't burning gearbox oil, the crank seals are usually fine. And smaller engines will show the effects of slightly off carburation more than a bigger engine.

It's dead easy to raise / lower the needles in those carbs, have you tried moving the needle clip to see if it improves things?

It's also easy to makes a quick test of whether it's rich or lean at mid-range rpm and medium throttle openings - just give it half choke. If it runs with less fluffiness, raise the needle. It it runs worse, lower the needle.

Good luck, I hope you can sort it without having to do open motor surgery.
I will give both a try & let you know how I get on. I tried upping the jets to compensate for the spannies, but it ran worse. I will try the needles as an easy option 1st. Cheers people :)

Bibio

27-07-19, 01:12 PM

mister c

28-07-19, 03:52 PM

Lovely :-)

small observation, to me its running a bit dry for a 2t e.g. not enough smoke. if the bike has a tank and pump for the oil try testing the output of the pump or if its new barrels then set the pump to "Run In" for the first 500 miles or so.

do a "plug chop" and check the plugs.

or it might just be you haven't ridden a 2t for a while...
I don't trust the oil pump, so am running it on 40:1 premix. When I left the MOT station I did "give it a little" (I'm still running it in as it's had a rebore) & I couldn't see too much behind me. I started sing "Purple Haze" in my head :p:D

mister c

31-07-19, 06:00 AM

Right, quick update.
The carburation is sorted (well, almost). Apparently, the good old Japanese like to mess with different size carb needles & needle jets within a 2 year lifespan, I had the wrong combination, hence why the bike wouldn't run right.
Using a magnifying glass showed that I had the wrong needles fitted after I noticed that I had 2 different sizes in my spares pot.

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/67630995_10220035418415220_6554004627795214336_n.j pg?_nc_cat=100&_nc_eui2=AeH7t3EIgxIKRPOQqeH8DSC8CDD5EBZszWWWbM5Zq si_yreYG46xGf-V8vaZPzwvyuHvLpDFEM27RZlg-NB1IpbiZQG96VcenOKaDiRMhDCZkw&_nc_oc=AQmnsUL71iHNe3XyGiDYmDM5DnBrMaufLHxolef8HkD M41kjynTiFzVQ2f3t7SA6LrU&_nc_ht=scontent-lhr3-1.xx&oh=5f09bb2fb8c1684e5862368682c36034&oe=5DE04B72

So, with the carbs removed, I fitted the new jets & needles, fired the bike up & went for a short ride. She's running 99% better, but still runs on a little when I come to a stop, so just need to adjust the mixture slightly & she should be right

https://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/67832912_10220033306682428_3818264907267178496_n.j pg?_nc_cat=104&_nc_eui2=AeFEzJpeiZemifq6KB2QCciP78bm-Sx4GjA6tKn-X5xwKSGONLGPffd035cVMy_ftdLYypH_-nlcmq00f-ClXo28ROo45BNeSzHodozPztpefA&_nc_oc=AQmJNuvM6YM1Ys1FBHEDOUelYHBXvnJDFRta8EiXL3e ZhDPBamS6IaxzxLOTffjXl0Y&_nc_ht=scontent-lhr3-1.xx&oh=910810e778aa5a1431eaeac0ed2369e9&oe=5DA0E854

Craig380

31-07-19, 06:46 AM

That's great news. Those needles on the left of the pic aren't really needles at all, they're more like pop rivets :)

garynortheast

31-07-19, 08:14 AM

Great stuff! Any chance of a vid of a fly past on the open road then Col?

mister c

02-08-19, 06:28 AM

I let my son have a little tootle up his road last night, so videoed it. The bike seems to be running okish now, but I should have rebuilt the crank as the centre bearing is quite noisy now. Obviously 40 years of non use has taken it's toll. She's coming off the road over the winter, so I'll probably strip the engine & send the crank away to Grampian in Liverpool for a rebuild ready for the summer next year.
dA48sVrKfew

andrewsmith

02-08-19, 12:06 PM