just picked this up today!

bottom end done! new oem rod,pin & all bearings & seals, technician states trans gears looked real good, Thats a relief, searching for new tranny gears can really bog a project down! My tech is a super nice dude, who runs the service dept of a small Honda dealer. He gets into these builds & painted the cases & replaced all the weak Suzuki case screws with Honda screws.





He also does fork & shock rebuilds, forks off an 84 rm250 & stock shock rebuilt, have to order a stiffer spring, forks got the full racetech upgrades springs, emulators ect.

cylinder was on standard bore, needed a first over bore, never been ported, but ports castings look rough, surely would benefit fron a little clean up... right?



I have never ported a cylinder, does anyone have any porting specs or suggestions?

this is how she sits at the moment, wont start reassembly until winter.

cleanup of the 84 DLS brakes

rebuilt water pump asy, needed everything, impeller shaft worn at seal, still availible from Suz, oem

rear wheel assy ready to go, new bearings & seals, sprocket, tube, bridgestone 403/404 tires, brakes cleaned &lubed, pads still had life, rim itself is in good condition, soaked spoke nipples with pb blaster was able to get them snug & true.
just cleaning up & making everything mechanically sound for a rider, no plating or powdercoat this time around, think I figured out, it makes more sense to go this route when you know its going to be ridden & raced. Maybe full restore of cosmetics after a season of riding it!

got a roller!

new clutch, all new waterpump assy, clutch side case all back together, was stumped for a while during reassembly, thought I lost the ball bearing at the end of the push rod during teardown, so, got another ball bearing & put into clutch lifter top hat, but pressure plate was not contacting last plate.....took basket back off, everything installed properly... was stumped? my brother was in my shop working on his rg500 gamma project & he came over & took top hat & tapped it on the bench, original ball bearing came out! guess I never lost it in the first place! I had done the same thing 3-4 times & it never came out, so I assumed it was gone.....

now I just have to lite a fire under my brothers ass to get my bike lift back!
Square 4 two stroke rotary valve rg 500 gamma engine almost done!

Pretty much done, fired it up, small leak from water pump cover, had to drain coolant & resurface the cover 2 times! Forgot to finish the build thread! I will post up some better photos of finished bike, looking forward to testing it out in the spring! Sounds great!

Rz! Awesome, my brothers rg 500 almost done, we fired it up a few weeks ago, unbelievable sounding!

bike still has original side # plates, faded & spray painted, but in good condition otherwise. Got these from Evo-MX, looks they will cover up most of the plates.

Pretty much done with the Z.. I"ve had the front wheel off about 25 times to try to iron out a sticking dls front brake, only does it sometimes, guess I"ll ride it & try to work it out.

Thanks MaxPower, been a long time since I rode a real full floater bike! I have to break this in & get the bugs worked out before Unadilla rewind.