Once upon a time two strokes were seen as a way to power a general purpose motorcycle

Let the repairs begin. The headlight opening had been roughly cut with a hacksaw. Better to file it clean…

…And use beading to make a custom grommet

Gear sensor and alternator cables had been squidged and crudely repaired at some point

The dash gives up its secrets

…and a little later, looking tidier

Andy’s Suzuki GT550L

Unlike many bikes that arrive at the RR workshop, Andy’s GT was very much a runner. He’d bought it in lockdown as a Canadian import, and done 12,000 miles on it since.

But electrically it was staggering about like a man who has walked into a gently swinging demolition ball. And Andy knew it.

As with almost any old bike, the GT’s electrical components revealed a past of wildly optimistic bodges. Every component, except the front brake switch and tail light, needed repairing or modifying. It takes a long, long time, but it’s all good fun. And eventually, you get to a point where you can start building the actual wiring loom.

I had a good go at getting the digital gear indicator display working again, but powering it up showed that only one element in the display was still working. Andy is going to hunt around for a replacement, but it may be a while. I made sure any new display could plug straight in. I also labelled the sensor wire colours, in case a different sensor needed its pins swapping around.

The wires came together well, and starting the motor afterwards proved Andy’s experience: it fired up right away, ran smoothly, and sounded gorgeous. The smoke billowed everywhere. Years ago, that kind of thing was just normal!

Andy had been looking for someone experienced with old bikes to give the GT a service and general check. Fortunately, I could oblige: just up the road is Rupe Farnsworth – builder and fettler of many a motor sickle, including some of my BSA A65. Once it’s been through both our workshops it should be ready for many more happy summers.

 

I always keep the battery leads clean and uncluttered, so that the insulators fit properly

New sub loom for the coils. Coil sub looms are always tricky to build, I find

The left side panel hides the rectifier (the back thing with fins) and regulator (black thing with green writing). Very old school, but it works

There’s a gear position display just above the neutral light, but all the elements were burned out. Andy is scouting around for a new one

Nice proportions