1979 Suzuki X5 Long term rebuild
 

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...08&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...59&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...64&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...ea&oe=5CD0C187


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

Re: 1979 Suzuki X5 Long term rebuild
 

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

Re: 1979 Suzuki X5 Long term rebuild
 

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.

Re: 1979 Suzuki X5 Long term rebuild
 

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

Re: 1979 Suzuki X5 Long term rebuild
 

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

Re: 1979 Suzuki X5 Long term rebuild
 

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


I'll be honest I can't remember on my original one, but all of the pictures I've seen, they are black


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 :)


It takes my mind away from reality Trev, plus, I should have a nice bike when it's all done :)

Re: 1979 Suzuki X5 Long term rebuild
 

looking superb :-)

Re: 1979 Suzuki X5 Long term rebuild
 

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...19&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...c4&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...b0&oe=5CCE6D16

Re: 1979 Suzuki X5 Long term rebuild
 

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

Re: 1979 Suzuki X5 Long term rebuild
 

It is mate, yes

Re: 1979 Suzuki X5 Long term rebuild
 

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...67&oe=5C8C1946

Re: 1979 Suzuki X5 Long term rebuild
 

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...64&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.

Re: 1979 Suzuki X5 Long term rebuild
 

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

Re: 1979 Suzuki X5 Long term rebuild
 

:smt119:smt120:smt088

Re: 1979 Suzuki X5 Long term rebuild
 

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

Re: 1979 Suzuki X5 Long term rebuild
 

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

Re: 1979 Suzuki X5 Long term rebuild
 

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...4c&oe=5CBFE4D3

Re: 1979 Suzuki X5 Long term rebuild
 

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...47&oe=5CB89096


https://scontent-lhr3-1.xx.fbcdn.net...8b&oe=5CD49EF7


https://scontent-lhr3-1.xx.fbcdn.net...47&oe=5CD4790C


https://scontent-lhr3-1.xx.fbcdn.net...71&oe=5CCF0D8F


https://scontent-lhr3-1.xx.fbcdn.net...c9&oe=5CCF9159


https://scontent-lhr3-1.xx.fbcdn.net...d3&oe=5CC375B1


https://scontent-lhr3-1.xx.fbcdn.net...aa&oe=5CD33F7E

Re: 1979 Suzuki X5 Long term rebuild
 

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.

Re: 1979 Suzuki X5 Long term rebuild
 

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

Re: 1979 Suzuki X5 Long term rebuild
 

Someone's put a very nice condition one up for sale on FB today...
https://www.facebook.com/marketplace...74615146698413

Re: 1979 Suzuki X5 Long term rebuild
 

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

Re: 1979 Suzuki X5 Long term rebuild
 

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!

Re: 1979 Suzuki X5 Long term rebuild
 

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...24&oe=5D20E030


https://scontent-lht6-1.xx.fbcdn.net...41&oe=5D2024A5


https://scontent-lht6-1.xx.fbcdn.net...26&oe=5D17B9B5


https://scontent-lht6-1.xx.fbcdn.net...45&oe=5CE893CB

1979 Suzuki X5 Long term rebuild
 

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_...100-t4832.html

Best wishes,

Alan

Re: 1979 Suzuki X5 Long term rebuild
 

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.

1979 Suzuki X5 Long term rebuild
 

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


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Re: 1979 Suzuki X5 Long term rebuild
 

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 :)

Re: 1979 Suzuki X5 Long term rebuild
 

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:

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 :(

Re: 1979 Suzuki X5 Long term rebuild
 

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.



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Re: 1979 Suzuki X5 Long term rebuild
 

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.


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Re: 1979 Suzuki X5 Long term rebuild
 

Nice one :)

Re: 1979 Suzuki X5 Long term rebuild
 

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

1979 Suzuki X5 Long term rebuild
 

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


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Re: 1979 Suzuki X5 Long term rebuild
 

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 :)

Re: 1979 Suzuki X5 Long term rebuild
 

Ooooh, it sounds SO good :)

Re: 1979 Suzuki X5 Long term rebuild
 

It is the 70s again!


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Re: 1979 Suzuki X5 Long term rebuild
 

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

Re: 1979 Suzuki X5 Long term rebuild
 

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

Re: 1979 Suzuki X5 Long term rebuild
 

Sounding good Col.