Suzi T500 Cobra Project
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Suzi T500 Cobra Project

This is a discussion on Suzi T500 Cobra Project within the Project Builds forums, part of the Caferacer.net Forums category; This thing has been sitting in the shop for a year or two and it's finally getting its turn under the gas axe. The plan ...

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Thread: Suzi T500 Cobra Project

  1. #1
    Member Sonreir's Avatar
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    Suzi T500 Cobra Project

    This thing has been sitting in the shop for a year or two and it's finally getting its turn under the gas axe. The plan is to chop it up and go with a hard tail café-scrambler-bobber thing

    I kid. Going for a full restoration. Hoping to have it looking like it just rolled off the assembly line.

    Issues so far:
    • Significant crack in the upper case and front sprocket cover (have new sprocket cover already, upper case will be welded)
    • Mismatched carbs (one is correct for the year, the other is from a later model)
    • Ding in the front fender might not be (easily?) reparable
    • Wiring is trashed (good thing I have a little experience in this area)
    • Headlight is not OEM and will need to be replaced
    • Cracked front fender strut (repairing an option?)
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    Last edited by Sonreir; 04-28-2017 at 12:41 PM. Reason: a couple of typos
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  2. #2
    jcw
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    Sonreir runs Spark Moto.
    They sell intelligent LiPoFe batteries. If anyone is in the market, you should check them out.
    I'm gonna get one for my next project.

    Love those titans, too.

  3. #3
    Senior Member Geeto67's Avatar
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    Quote Originally Posted by Sonreir View Post
    The plan is to chop it up and go with a hard tail café-scrambler-bobber thing
    Can't you just pick one? I mean you list three things that aren't even remotely related. If it's a hardtail it's a chopper end of story (unless you set it up as a hardtail flat tracker then it's a bobber).

    Here is a resource on how to race prep a T500:
    Suzuki 500 race preparation
    some of the info is dated but it's all still workable.

    Don't hardtail the thing, you'll just ruin it.

    It's too bad you are on the complete opposite side of the country as I have a complete cobra engine sitting in my NY storage. it would save you the cost of welding.
    Ever tried. Ever failed. No matter. Try Again. Fail again. Fail better.
    - Samuel Beckett
    A tool is just an opportunity with a handle
    - Kevin Kelly

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  5. #4
    jcw
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    He's not gonna.
    He was just kidding
    He is one of the smart ones over there.
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  6. #5
    Member Sonreir's Avatar
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    Most of the parts have been sent off for blasting and powder.

    Engine tear down has begin.

    Any tips for removing the head bolts? I was able to get two of them using the double nut method, but I broke my wrench before I could get the others.

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    Senior Member Tanshanomi's Avatar
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    Quote Originally Posted by Geeto67 View Post
    Don't hardtail the thing, you'll just ruin it.
    We didn't get to this guy in time.

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  8. #7
    jcw
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    If it's really stuck, I'd consider welding a larger nut that would slide all the way down the bolt.

    Between the heat of welding and the better torque you can apply to the stud, I'd think it would give you the best chance of getting it out...

    Or snap it off.

  9. #8
    Senior Member Diamondj's Avatar
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    I don't usually remove them. Are you doing this to get them replated? You will probably need to use a torch on the cases to help get them loose. Make a half/half mixture of kerosene and ATF to soak these in-between heating cycles.

  10. #9
    Senior Member Geeto67's Avatar
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    Quote Originally Posted by Tanshanomi View Post
    We didn't get to this guy in time.

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    There was a guy years ago who had a T500 chopper featured in "the Horse" and the bike ran straight pipes. Not Chambers with no muffler, but a straight open piece of pipe. He complained about not being able to jet it right in the article. I stopped reading the horse shortly after that.
    Ever tried. Ever failed. No matter. Try Again. Fail again. Fail better.
    - Samuel Beckett
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    - Kevin Kelly

  11. #10
    Senior Member hillsy's Avatar
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    Stud removal sockets:

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