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Suzuki X5 long term project
Well, here we go, time to bore you all rigid with one of my infamous rebuild threads. :)
So, way back in the day, I was a snotty nosed 16 year old that had always been around motorbikes & had big plans of owning my own one day. I wasn't going to have a moped like my mates so started to save up the deposit for a Suzuki X7 250. Christmas 1978 and, with the money from Christmas as well as the small amount I'd saved, I walked into Websters Motorcycles in Crewe with the hope of buying a new X7. Reality struck when the owner told me that I didn't have enough money & that the insurance would be over £100 TPFT (I was earning £25 a week then). They did have an alternative, it was £100 cheaper at £675 & the insurance was a lot cheaper, so, deposit put down, HP documents signed, enter into my life, a blue Suzuki X5 200 Reg number SMB163V. I had to wait 3 months before I could pick her up, so spent every day walking past the showroom looking at my new bike in the window until, on 2nd March 1979 I walked in, picked up the keys & rode off into the sunset. No CBT, no training, just get on & ride off. This started my proper love affair with motorcycling. https://scontent-lhr3-1.xx.fbcdn.net...e1&oe=5C4358F7 Fast forward nearly 40 years & I saw an advert on Ebay, a 1979 Suzuki GT200 in pieces for £350, which didn't sell. I made contact with the owner & secured the deal for £300 & collected it a few days later from Lancashire. https://scontent-lhr3-1.xx.fbcdn.net...90&oe=5C4A938F It came in handy being in pieces, it fitted straight into the back of the car :p, but I was taking a massive risk because I couldn't tell if everything was there https://scontent-lhr3-1.xx.fbcdn.net...fc&oe=5C88C2A6 To be continued............... |
Re: Suzuki X5 long term project
Yay! I have so missed your build threads Col, looking forward to seeing this progress.
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Re: Suzuki X5 long term project
Not boring Col, build threads are great
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Re: Suzuki X5 long term project
Looking forward to this :D Thanks Col :D
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Subscribed : )
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Re: Suzuki X5 long term project
I'm guessing you have two bikes there, or at least most of a second one, judging by the three clocks, four fork lowers (but only three stanchions?), four side panels, two engines, four downtubes... Sounds like the sort of fun I wish I had the nouse to have a go at.
Keep us posted Col as so many of us older farts on here remember those little 2-smokes with misty eyes. |
Re: Suzuki X5 long term project
looking forward to this one :-)
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Re: Suzuki X5 long term project
Cheers people. Here's the next installment.
Once I got the bits home I was like a kid with a new toy. I hadn't felt so excited about a project as with this one, so I started to sift through all of the boxes of parts to see what I had. As Sir trev says there were loads of parts, three full engines in various states of disrepair, fork legs, wheels, downpipes, the list went on. One thing that was missing was virtually every nut & bolt, DOH! Luckily the larger engine & wheel bolts were there, so it was just the smaller fixings, which were going to be replaced with stainless items anyway. I sifted through the parts, finding the best items & started to put the jigsaw together with 2nd hand bolts that have been kept from previous rebuilds to see if I had a full bike, which I had. https://scontent-lhr3-1.xx.fbcdn.net...49&oe=5C7C6B5E https://scontent-lhr3-1.xx.fbcdn.net...11&oe=5C7DD747 So now the real rebuild starts. 1st things 1st. I stripped her back down, bagged up all of the large bolts & springs & took them to the local platers for zinc plating. While they were away, the frame was taken for powder coating & I scoured Ebay for stainless bolts & found a company called Kay's Fasteners that sold stainless flange bolts & nuts, which looked far better than standard, so ordered a selection of sizes. While I was waiting for the big bits to be done, I ordered new swinging arm bushes, rear shock nuts & rear brake torque arm bolts direct from Suzuki, boy, they know how to charge! 1st to be done was the plating, so that was taken into the shed until the frame arrived. https://scontent-lhr3-1.xx.fbcdn.net...dd&oe=5C7AA69B After a couple of weeks of waiting, I rang the powder coaters to see if the frame had been done "Sorry mate, forgot to call you, yes it's done". So off I trundled & collected the frame, swing arm & stands https://scontent-lhr3-1.xx.fbcdn.net...2f&oe=5C4315F8 So, we have a frame, a load of plated bolts & springs & new headrace bearings, it would be rude not to put the jigsaw bits back together. https://scontent-lhr3-1.xx.fbcdn.net...9d&oe=5C89198E https://scontent-lhr3-1.xx.fbcdn.net...c1&oe=5C50A9D0 Next on the agenda were the wheels. Being honest they weren't in too bad a condition, but it still took over 2 hours of wire wool & Autosol to get each wheel lookng something like. Once I'd cleaned them I sat down, very patiently & painted the insides black. https://scontent-lhr3-1.xx.fbcdn.net...84&oe=5C4D9A71 I had about 3 sets of forks, but each set of stanctions were quite badly rusted, so started to look at rechroming. I found a company about 4 miles from me, but they wanted to charge £165, which I thought was a little steep. Somebody on the X5 Facebook page said that they had used GS125 stanctions in their x5 lowers. I found a set on Ebay for 70 quid, they were in exceptional condition, so bought them, stripped & cleaned the fork legs, fitted new seals & fitted the forks to the bike. This is where the next problem occured. As I tightened the right fork leg, the bottom yoke decided to break. It turned out that there was a crack in it that I hadn't seen. Luckily I had another one, so cleaned it, sprayed it black & fitted it back on the frame. Job done. https://scontent-lhr3-1.xx.fbcdn.net...41&oe=5C3DB340 Other things that got the clean & paint attention were the clocks, & rear end, it's starting to look like a motorbike now. https://scontent-lhr3-1.xx.fbcdn.net...c6&oe=5C7B345D https://scontent-lhr3-1.xx.fbcdn.net...1b&oe=5C825B63 https://scontent-lhr3-1.xx.fbcdn.net...a7&oe=5C4D3E00 I turned my attention to the engine. I had 3 engines in bits, so tried to find the best parts to build one good base to start with. I cleaned & sprayed the crankcase covers & put the bottom end together. All of the top ends were in a bit of a state with oversize pistons between .5 & 1mm, not too good to be honest as I wanted to have them rebored to be as good as new. Luckily a friend of mine contacted me & said that his mate had a fully rebuilt engine that I could have for £100. I bit his hand off & said yes. Unfortunately, when i came to strip the engine, it was in quite a mess. The only plus point was that it was still on standard size barrels & pistons. I told my mate who said that his mate would take £50 for it. Sold! I sent the barrels away to Grampian motors for a rebore. They had a week's turnaround & use decent, Japanese oversize pistons. They did a great job. https://scontent-lhr3-1.xx.fbcdn.net...ce&oe=5C4E3B03 https://scontent-lhr3-1.xx.fbcdn.net...65&oe=5C3C8259 https://scontent-lhr3-1.xx.fbcdn.net...41&oe=5C78D6E8 So, we now have a rolling chassis with a bottom end of an engine all looking rather nice. Next step will be to start on the smaller, more niggly bits that take the time & money. |
Re: Suzuki X5 long term project
Well done Col, this is looking really good already.
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Re: Suzuki X5 long term project
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Front brake lever was the next on the agenda. I ordered a new seal kit, stripped the master cylinder, cleaned it & rebuilt it. https://scontent-lhr3-1.xx.fbcdn.net...2d&oe=5C800C55 https://scontent-lhr3-1.xx.fbcdn.net...2b&oe=5C83BC70 Another part that was missing was the headlamp, so ordered one off Ebay, it's a pattern 7" unit which looks identical to the original, but has the benefit of an H4 fitting, so It'll be a lot brighter if I ever ride it at night (which I doubt). https://scontent-lhr3-1.xx.fbcdn.net...b5&oe=5C427D9E I cleaned up the sprocket drive & rear brake cover & fitted those to the rear wheel, then onto the bike. I'm trying not to polish things too much as I want the bike to be as close to standard as possible. https://scontent-lhr3-1.xx.fbcdn.net...e4&oe=5C461C8E The single front disc was looking a bit sad, so I cleaned the surface rust with fine wire wool, then painted the centre black. I've used the original bolts to fix it to the front wheel, but will buy some genuine ones once I fit the tyres. The front caliper was a bit more involved, so I'll leave that for another day. https://scontent-lhr3-1.xx.fbcdn.net...c1&oe=5C83BA7B https://scontent-lhr3-1.xx.fbcdn.net...7b&oe=5C822887 So, we now have a rolling chassis, I brought her out into the yard to get a couple of decent pictures of the progress. I used to have a cheap Chinese phone, so apologies for the quality of the pictures so far. https://lh3.googleusercontent.com/tv...=w1024-h683-no Cleaned the 2 stroke oil container as best as I could, but it still has a red tint to it, so will have to do. I'm going to run the bike on premix anyway, so it's surplus to requirements anyway. https://scontent-lhr3-1.xx.fbcdn.net...a0&oe=5C4CBFA5 Next to get the treatment was the wiring harness. Both of the ones I had were in quite a bad way & I did think about re wiring the whole bike from scratch, but opted to strip the best of the 2 down & recover it with non adhesive tape & fix any problems as I went. I hate electrics, but it has to be done. https://scontent-lhr3-1.xx.fbcdn.net...4b&oe=5C78F52D https://scontent-lhr3-1.xx.fbcdn.net...a0&oe=5C41C0AC Wednesday morning & the postman came knocking...... Ooh, barrels & pistons have been returned from Grampian. I was like a 4 year old at Christmas with bits of cardboard & paper being excitedly ripped apart to see what sort of job they had done. I wasn't disappointed, I would certainly recommend them to anybody. The barrels have been honed to perfection & the pistons look gorgeous, so time to go & fit them with my newly purchased gasket set. https://scontent-lhr3-1.xx.fbcdn.net...7d&oe=5C86E7DE I also stripped one of the 3 sets of carbs down, threw them in my ultrasonic cleaner to get them as clean as possible & get rid of any old petrol that might be blocking any channels. So, we are ready for an engine rebuild :) https://scontent-lhr3-1.xx.fbcdn.net...04&oe=5C3DCCC1 This is where I encountered another problem. I have 4 crankshafts, 3 of which have a noisy centre bearing, so chose number 4. The problem was that this one would only turn 180 degrees then tighten up. I was trying to see what the problem was & could only think that the crank was bent. I tried it in another crankcase with the same problem, so I was now in a quandry as I wanted to see if the engine would run. I chose the best crank of the other 3 & continued with the rebuild. The nice thing with 2 strokes is that it only takes about an hour to remove & strip an engine, so I'll send the crank to Grampian for a rebuild later. https://scontent-lhr3-1.xx.fbcdn.net...a2&oe=5C43BEB9 I fitted new side decals to the engine, then the airbox & the rusty silencers. It's time to see if the old girl fires into life. I checked the coils, we had a spark, so fitted the tank, poured in some 2 stroke & used an old kickstart & after the 4th kcik, she fired into life! She sounds nice, but needs the carbs setting up, which will be done when I rebuild the motor again. At least I know that I have a runner, I'm like a pig in muck.
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Re: Suzuki X5 long term project
This is awesome. Makes me want to get a bike project, even though I have a T2 VW to do!
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Re: Suzuki X5 long term project
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Re: Suzuki X5 long term project
Oh wow, that's looking great. I had a W-reg X5 in the same blue colour scheme when I was 18 (because of the cheaper sub-200cc insurance). They were FAST too, because they were so light. After I fitted Michelin M38s it never ran out of grip, it was the only bike I've had that felt comfortable scraping the footrests and the toes of my DM boots :D
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Re: Suzuki X5 long term project
Lovely job.
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Re: Suzuki X5 long term project
Sounds great already. And I love that the engine roundels are the same as those that were on my 83 GSX250EZ. Ah memories.
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Re: Suzuki X5 long term project
Makes me nostalgic for my CB250rsd project that I never quite saw through before realising I needed to sell it to keep the SV running.
. https://66.media.tumblr.com/73bcc2b7...q8e5o1_500.jpg |
Re: Suzuki X5 long term project
It was at this point that I took 6 months away from work to circumnavigate Britain in our newly aquired 25 year old motorhome. I have reached the grand old age of 55 & could draw some money from my private pension, so myself & my wife decided to do something before we were too old to appreciate the memories.
So, while we were away I though that I'd get the rechroming done. We have a plating company in Crewe, so I took a few items down for them to have a look at & price up. "It'll take about 12 weeks mate" said the assistant behind the counter. "That's fine, I'm away for about 6 months" I replied. The small parts were quite expensive price - wise, but the exhausts nearly made me fall over. They wanted £360 for the silencers & £60 for the downpipes, I told them that I'd leave those for the time being. So, off we went on our travels. I have been busy looking for a job since I got back, so haven't made a lot of progress on the bike, but did call round to the platers as I hadn't heard from them in 7 months....... Guess what? They hadn't done them :( The parts had been put on a shelf & forgotten about. "I'll have them done in a couple of days for you mate". How can they quote 12 weeks originally, then do them in 2 days? I'm still trying to work that one out. They did make a nice job though. https://scontent-lhr3-1.xx.fbcdn.net...fa&oe=5C8561EB What you are looking at there ladies & gents is £200 worth of chrome plating, scares the living daylights out of me. It was tme to fit the shiney bits to the bike https://scontent-lhr3-1.xx.fbcdn.net...1a&oe=5C8776CA https://scontent-lhr3-1.xx.fbcdn.net...2d&oe=5C88151A Next was the front brake caliper. The piston was solid in the caliper, so I had to heat the caliper & be a little brutal with a pair of waterpump pliers to extract the piston. It did move eventually, so that was one problem solved. I had ordered a caliper rebuild kit which came with new seals & bleed nipple, so tried to remove the nipple, which was seized solid into the caliper, things were a little harder this time because I didn't want to snap the nipple in the caliper as calipers are as rare as rocking horse poo. I used plenty of heat & with some gentle persuation it started to move & after about 15 minutes, the nipple was sat smouldering on the bench. Icleaned & painted the caliper, fitted the new seals & pads & placed it on the bike. https://scontent-lhr3-1.xx.fbcdn.net...c9&oe=5C41AA94 So, this is where I'm up to at present. I still have plenty to do, but I'm back at work full time at the moment as my boss is on holiday. I have won some very rare, nos Allspeed Expansion chambers on good old Ebay, but they are from a Danish seller, so hoping that it isn't a scam. I've paid by Paypal, so should get my money back if it is. Watch this space. https://i.ebayimg.com/images/g/DkQAA...EH/s-l1600.jpg |
Re: Suzuki X5 long term project
Showed this to Mrs Kenzie. She wants a project bike now...
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Re: Suzuki X5 long term project
I think I'll need to come and hear (and smell!) this running when it's finished. :smt046
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Re: Suzuki X5 long term project
Been having issues with the electric start, every time I pressed the button, the fuse would blow. So I've left well alone for a week, been to it this morning with a fresh mind & noticed that I had got some of the wiring wrong, so righted it & the old girl sparked into life. I'm one happy bunny :)
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Re: Suzuki X5 long term project
looking superb Col :-)
one thing i will say is i have never seen expansion chambers that the welds were not dressed, even back in the day all of them were shiny especially well known makes. never thought about making your own chroming tank for small parts? |
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Re: Suzuki X5 long term project
That's looking lovely Col. Not far from finished I'd guess?
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Re: Suzuki X5 long term project
Vid doesn't play for me?.
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Re: Suzuki X5 long term project
One of the bolts from my caliper was missing, so routed around on the net to find that only genuine parts were available at £27.00! I started to do a little homework and found that a 1978 gs550 caliper had the same bolts in, there was one on Ebay for £20.00 posted. It arrived today & I had to go & play. I also derusted the brake line guide. https://uploads.tapatalk-cdn.com/201...60aa0385ed.jpghttps://uploads.tapatalk-cdn.com/201...80815532e7.jpghttps://uploads.tapatalk-cdn.com/201...b201c79c81.jpghttps://uploads.tapatalk-cdn.com/201...b10ae45163.jpghttps://uploads.tapatalk-cdn.com/201...2ef5183956.jpg
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Re: Suzuki X5 long term project
Well, these turned up late last night. My ebay win. I know what I'll be doing later. Video to follow :) https://uploads.tapatalk-cdn.com/201...0281d278ad.jpg
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Re: Suzuki X5 long term project
Ha ha! That looks like it might be loud!
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Re: Suzuki X5 long term project
I've just picked up a polishing wheel set for my hand drill from Lidl that they're selling at the moment. Just in case it's of any use :)
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So, as stated just, I had to trial fit the Allspeeds. They were "brand new" as described & they even came with the original Gibson decals in a separate bag. When I was a pimply, fat 17 year old oik I always wanted a set of Microns or Allspeeds for my X5, but could never afford them, so I was transported back to 1979 & I was 17 again. 6am on Thursday & I'm in my shed, spanners in hand fitting them to the bike. The quality is there to be seen & everything lined up perfectly & only took about 10 minutes to fit. https://scontent-lht6-1.xx.fbcdn.net...59&oe=5C7A1321 https://scontent-lht6-1.xx.fbcdn.net...a0&oe=5C7A1C1A https://scontent-lht6-1.xx.fbcdn.net...78&oe=5C3F742F Saying that these pipes were nearly 40 years old, they are in really good condition. I have a feeling that they had surface rust on them that the Danish owner had cleaned off before shipping due to the wire wheel marks visible in the steel. I'm going to see if they will buff up, if not i have some High temp paint that I used to spray my boss's Red Rocket exhaust with that looks nice, so we'll see. Now, it was 6:30am & I couldn't resist fitting the tank & firing the bike up to see how she sounded. A few prods on the kickstart & she fired into life, the hairs on the back of my neck stood up, I'm one happy boy :)
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Re: Suzuki X5 long term project
That sound takes me back a few years. I never had two strokes but quite a lot of folks I knew did back in the 70s and 80s.
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Never owned a two stroke then, loaned a friend my cg125 so she had something a bit easier to pass her test on, I had her RD200 for a couple of days. That was a wild machine compared the the CG |
Re: Suzuki X5 long term project
Bet your neighbours love you doing that a silly o'clock! Sounds awesome, reminds me of my old RGV 250L. Miss that bike.
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Painted the cans today as they wouldn't polish uphttps://uploads.tapatalk-cdn.com/201...d003deaea7.jpghttps://uploads.tapatalk-cdn.com/201...d503c294c1.jpg Sent from my BND-L21 using Tapatalk |
Re: Suzuki X5 long term project
Nice! I can't wait to see and hear this in the flesh (we'll, the metal, anyway!).
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Re: Suzuki X5 long term project
Been busy with other things of present, so not had too much time for the bike. I have finished the silencers this evening. A 2nd coat of high temp paint, end caps polished & stickers applied. Hopefully, she'll have some tyres next week [emoji846]https://uploads.tapatalk-cdn.com/201...fad7ecbdb3.jpghttps://uploads.tapatalk-cdn.com/201...aa9fb6f7be.jpg
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Re: Suzuki X5 long term project
Looking good Col. Bet you can't wait for it to be finished and a decent day to get it out for a spin!
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