Suzuki RG500 Teardown - Part 1
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- เผยแพร่เมื่อ 5 ก.พ. 2025
- Part 1 of the Suzuki RG500 teardown.......... What? you want more description?! Its fucking awesome - jesus - what more do you want?!
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You do videos trying to “teach” with yourself coming off as having some engineering training, at least that’s what I thought when I first watched a few of your videos. Now after watching several it’s getting harder and harder to take you seriously with your incessant cussing and I can only imagine the pile of spit laying everywhere (nothing against cussing but you take it to extreme and sound like your spitting everywhere and I notice you fumbles for proper words a lot)...anyway, after this being the first video I watched with you doing anything hands on away from your white board I now know you lack any experience with turning wrenches therefore I suspect all your advice merely regurgitated from wherever you where schooled not from first hand experience in building motorcycles/motorcycle engines.
Your lack of quality tools and the way your fumble with them and the nuts and bolts you remove are a DEAD GIVEAWAY...the way you speak, your lack of diction giveaway a lot too...if you want to sell yourself as a highly knowledgeable engineering minded motorcycle enthusiast you should think about working on your presentation. Professionalism goes along way. You may be able to sell yourself to youngsters with there first motorcycle in need of help but that’s about it.
Subscriber lost
Oh sweet and arsehole comment -
"You do videos trying to “teach” with yourself coming off as having some engineering training, at least that’s what I thought when I first watched a few of your videos. Now after watching several it’s getting harder and harder to take you seriously with your incessant cussing and I can only imagine the pile of spit laying everywhere (nothing against cussing but you take it to extreme and sound like your spitting everywhere"
- Massive moaning rant with no real conclusion......
"and I notice you fumbles for proper words a lot)"
- Finally something to with a point. Have you tried doing this???
"anyway, after this being the first video I watched with you doing
anything hands on away from your white board I now know you lack any experience with turning wrenches therefore I suspect all your advice merely regurgitated from wherever you where schooled not from first hand experience in building motorcycles/motorcycle engines."
- No context or anything. If you have some examples then fuking come out with it. Secondly to this point, I'm not a mechanic. So I don't do this 9 to 5. But I'm talking your comment as a bitching moan - because you haven't outlined any points......
"I suspect all your advice merely regurgitated from wherever you where schooled not from first hand experience in building
motorcycles/motorcycle engines."
- Again no context or examples. Secondly this isn't engine building. Engine building is machining etc not assembly. Anyone with a book can assemble an engine.
"Your lack of quality tools and the way your fumble with them and the nuts and bolts you remove are a DEAD GIVEAWAY"
- Quality? As in Facom isn't a quality tool? Or a you one of those mugs who only get ripped off by the snap-on wagon?
"the way you speak, your lack of diction giveaway a lot too.."
- A giveaway of what???
"if you want to sell yourself as a highly knowledgeable engineering minded motorcycle enthusiast you should think about working on your presentation."
- LMAO I have a full time job. As a mechnical engineer. Enough said.
"Professionalism goes along way."
- to where? And how long does it take to get there?
"You may be able to sell yourself to youngsters with there first motorcycle in need of help but that’s about it."
- for someone who goes on about 'presentation' I thought you would at least have some grammer. It's 'their' not 'there'.
"Subscriber lost"
- Good. I'm not too keen on dickheads. Especially not those who call themselves 'busaboy'
There's (the correct use of there) a channel you'll love. It's called delboys garage. He lies and bullshits his way through loads of subjects - but at least he doesn't swear.
busaboy, I've come across your precious type of "professionalism" many times, from my experience as an engineering project manager. Usually accompanied by politically correct language, management buzz phrases and complete incompetence. Why waste time explaining that when a "why don't you just fuck off" will do? Not swearing does not make anyone professional
busaboy
Listen, because your mommy said swearing is bad doesn't mean the whole world has to follow that rule....grow the hell up. Ever been in a shop past the service counter? I doubt it. Matt is saying what is going through everyone's mind when they work on stuff.
BTW: www.huffingtonpost.ca/2016/09/27/swear-words-intelligence_n_12213206.html
Studies show intelligent people swear more than dummies. Me thinks I know what column you fall into.
Have fun, good work The Workshop.
At least busaboy is smart enough to stop watching, which is more than I can say for a lot of whiners using up oxygen on this planet.
What a goon lol
This is why forceful castration should be a thing to stop people like you from repopulating
Advice I give to any non mechanics, IE those not trained to memorize exactly where every part came from after disassembly, is simply use a cam and take pics along the way to refer back to.
Marking and storing everything is good but even then with enough marks on parts that can get confusing for some.
So that’s why that macaroni guys english is indecipherable, he’s writing backwards from the inside of his plastic box brain. I really don’t get people who leave such negative commentary. Don’t let it bother you. The channel is top notch!
I couldn't stop grinning throughout this! :). Defo subscribed. Great work.
Ahh this takes me back to the old days of doing top end rebuilds on a TZ 750 at the racetrack. 👍👍
"...but you find out the postman fancies you."
lost it
I don't like two strokes ( my horrible Mercury 2,5 keeps me busy enough) but am enjoying this teardown. Looking forward to more of this. How can anyone shove an imperial bolt into a metric threaded hole is beyond me....
Write in normal way on the top, turn around and trace the letters. Impress your friends by using very neat handwriting and after tracing on the backside, wipe the writing away from the top with booze wipes. (and then tell them about this handy trick, they will be amazed how neatly you write backwards)
13 minutes in and you just had to mention the dreaded Copper Grease...........not only that, but again at 31 minutes. Really enjoyed this vid Matt. Roll on part 2👍👍👍
Part 2 in about 1 hour-ish*
*(no promises, or refunds)
Hi Matt.
Back in the day you fixed stuff with what you had as metric was not readily available
it was mostly BSF & WITWORTH. Great video's Great Channel
Yeah but this was 1985 onwards not 1954. These bikes were expensive and always have been since.
Sorry about that, B&Q didn't have the right size bolts.
9:23 My exact words on every single project, only started once i hit my 30s
Paint pens are so useful it's unreal always using them
I find those ball end allen keys tend to strip out cap screws when they are tight like that.
I break then loose with a normal one first then go at it with the ball end for speed of removal.
Or maybe I am just a hammer head haha.
You need to try the Wera ones I have - they are the bollox!
Lack of carbon on rear pots is due too water ingress.
Best way to go on broken thread? In this case i think is weld with castoline or durafix the bore, drill and tap again in mill bench. Even you can do this.
It's a fuckin' heirloom! That cracked me the fuck up! Haven't worked on a rotary valve engine since 1980 something; an old AP50. Great video.
Every project I do starts with a trip to the grocery store for the xl ziplock sandwich bags. Everything gets labeled and put in its own bag and dumped in a 5gal bucket
Omg, my brother had one of those things ported, pipes from a guy called alex may's here in Canada, that came of the walter wolf /leitner and busch race gamma's back in 85, orient express pistons in it i think bumped up the compression a bit, was balanced out as well.. bit of a light switch that way..zero under 6500..then she came on the pipe..wow!! cool machine..you may have heard it over in the uk when he hit the power band..cops certainly did.. his friend crashed it driving it home for him after he got nicked.. spent a year in the hosp.. fuck.. good on ya for showing the guts of the old square 4.. !!!
Andy sent me! Great video
Andy?
Andy's motorcycle obsessions! He has a link to your video.
RG 500! My first love!
Obviously fitted with he infamous non OEM POPS i.e. Previous Owner Problems Syndrome!
Brilliant, thanks Matt
The damage in the first head you took off reminded me of an RD250 I had a million years ago.I think the electrode had dropped out of the plug,If I remember correctly.
Either that or the piston rings shite the bed. I think these are different cylinders than the original - we'll have to investigate further.
Yep damage looks like bits of busted ring to my eye.
Could be rings,maybe that might explain the rebore?
AuMechanic agreed
That intro ❤️
my god the flashback of memories!!I mean the cartoon...
Hi Matt, enjoy your videos, just a thought, but would like to hear your take on Helicoils, as I’ve had them unwind, I now use Timesert with much better effect. Maybe worth a comparison? Cheers Si
I guess the only problem with that engine was the moron that rebuild it the last time after it chewed some shite on one cylinder.
Nice looking pistons! I might have missed it, how many miles on that engine? Pissed me off as well to have seen those washers and wrong threaded bolts FFS, it's pocket change to buy 2-3 new ones, this way it made it way worse...
"Nice looking pistons! I might have missed it, how many miles on that engine? "
- don't know, its never been registered.
The pistons say 0.5, Im wondering if its been overbored by .5mm already? Maybe that's why the pistons are so clean, I'd check that bore.
Why so I need to check the bore? They are 0.5 oversized.
I meant to see if it is overbore. Guess that makes sense lol. They're steel liners right not nikasil? Not sure if they had that back then.
Yes they had it back then - but the RG500 has steel liners (well I'm almost 99% sure) I'll check tomorrow.
I have an 1988 RGV250 and it has nikasil lined bores
Thats crazy, I wonder how the process compares to the way we do it now. FYI if anyone ever needs any replating done I highly recommend Millenium Technologies. Their coating has lasted ages in my 2 stroke KTM that gets abused and tossed aside like a red headed step child. Absolutely 0 wear still looks brand new.
Ring gap on Intake-side cause of "thermical reasons"? On a two-stroke? Are you serious?
Try them with the gap to the exhaus and you will see what happens... rings catch on exhaust port, finished.
Cheers
Thermical - don't you mean thermal? And yes I've been through this in several videos in the past. Pin placement dodges ports - as there are ports everywhere. The gap is on the opposite side to the exhaust port be cause heat. The hot side of the rings wears out more than the 'cool' side. Hence thermal reasons. I.e I can't be arsed to explain again so moving on....
No thermical is a mixture of thermal and comical.
You sir are a fucking legend...
7:48-7:52 LMFAO You are hilarious Matt!! Love it :D
F*cking awesome Matt, iconic engine & 1 I happen to have, couldn't be better. I see you're doing it in special sections (yes! PV set-up & carb set-up will be especially welcome). Top man! If you ever happen on the RD500 motor I hope you'll do it too (I know it sounds unlikely - but how likely was an RG5 turning up?) Gsxr1000K1 or 750/600 type motor too would be great if it's ever possible.....a new series to rival Haynes? lol keep it right way up mate :) .Just looking at the motor as you tear it down, not only no carbon but those ports look really smooth - has it been tuned?
Fuck am I jealous that you get to with that thing, so bloody awesome. One weird (to me) thing I saw was the combined base gaskets, my yamaha tzr250 has a seperate base gasket for each cylinder. I've never seen a combined one like that. I guess suzuki did things different to yamaha. You're a lucky fuck getting to handle that kind of greatness.
Ahh here we go, the 2 stroke mechanic on his normal day, not such a thing, all the cursing words, made me remember when i work on my dad's bike xD
I never knew the RG fired like that, basically a 500 twin. I wonder if the RD 500 was the same or how the infamous Yam TZ750 which was an inline 4.
more of a 250 twin x2
twin twin two stroke 500cc madness.
Engine "U"
Yes mate
I dont see any damage on the piston dome did someone rebuild it and not clean up that combustion chamber? just asking for detonation with all those sharp bits..
The pistons crowns are stamped 0.5 so yea its been rebored after it blew up.
Ya i seen that im wondering who would put it back together without milling that head though. All those nicks and gouges are just about guaranteeing pre-ignition leading to detonation.
I get so mad everytime I work on older stuff and some dope has added random hardware to it etc. I love having to carry 5 different wrenches to remove parts because there is 5 different fasteners on it..
I wonder why you don't want to use Helicoil's as your first option? I use them alot in these situations they work fine for me.
What is your reason NOT to use them?
We'll get to this.....
well i saw once somekind of plastic used for head gasket on a bike my dad repaired once. he could not get around what the f ... is going on till he disassembled the the head. it was starting on one turn till it heated up and died.
Brilliant vid
I get my plastic boxes from the candy store.
They will give you a gazillion of them for free.
Thats NICE.
this will be good
Those heads are missing some dome nuts, it probably leaked a bit.
That's a sexy engine
An old mate of mine had the cylinder on his old YZ490 and Helicoiled and it was never right, perhaps the people who done it did it wrong but I'd go drill and tap if possible after what I've experienced with helicoils
Everyone should watch this again but this time picture yourself back a school and Matt is your teacher lol.
I would’ve leant a shit load more if my teacher used the same method as Matt. Even if I ended up a shit bike mechanic I would be able to swear so eloquently lol.
Oy get to fucking bed Matt! It’s nearly 02 fucking 30 lol
I just got my '88 RGV250 on the road. It is the most ridiculous, impractical, idiotic street bike I have ever experienced. But god it's fun. Wish this series had started last August. Ah well. Now I get to see all the things I did wrong. LOL
I bought a Kwaka KR-1 when they came out, same period as the RGV. Total nutter bastard bikes the pair of them.
Totally dude. Bet the KR-1 was fun, though.
that is a badass engine
Was torque striping exhaust manifold bolts one day and one of the old lads at the shop said “that white paint pen isn’t going to tighten those bolts if you leave them loose” had a good laugh at the old prick but needless to say I don’t use it for external fasteners anymore. Fucking funny slating the butcher who slapped it together before you got into it!
Questiin about the sv1000.does it suffer with clutch chudder and if so how to remedy it
That's coming soon.
Great to watch :)
lmao @ weed baggies. You're the man!
Why all the copper washers, why isn't galvanic corrosion a concern?
Dude it is a race engine - they don't give a fuck and galvanic corrosion is a slow process unless you drop it in the sea.
I think you mean "race engine"
Not an issue. I''ve had mine since '85 with zero galvanic corrosion.
What happened to the original bolts? Looks like the stripped it all out.
Fuck knows
Why have two pistons at tdc at the same time? Why not rotate one crank 90 degrees and make it sound like a v8?
LOL becausee power is eveything - not sound
The Workshop Why would it reduce the power? R1 has 90 degrees fireing order and that is suposedly better somehow.
The way it is gives it perfect primary and secondary balance. Which means less shaking which means the parts can be lighter.
Amazing engine.
Is it your bike?
No. Part 2 explains in more detail
How is this engine compared to the RD500?
Basically the same.
This is a 500ccGP engine. RDs are sport tourer engines; that's why RDa have different induction methods on the front and the rear cylinders.
Not so. RDs fall out of tune after a few hundred miles. Gammas stay i tune until the pistons wear out.
>testbed
Bet the guy that gave you the thing won't be too thrilled about that freudian slip, lmao.
either cold as fook or pretty excited to start tearing it down at the start eh?!
Eyup Northern.New 1st oversize pistons.When youve rebuilt it,Ill give you some Wotsits to give it me!
Isn't the first OS piston a 0.25 then increments of 0.25 up to 2.00?
You might be right with that!
The spline style on the kick starter, is it better/stronger than the normal "V" tooth or did Suzi just want to be different? (stripped a few kickers on my old GS750, can't afford to do owt about it, just curious)
Well kinda yeah - they have a thicker root - it depends on the OD of the shaft - deeper 'v's mean that its actually weaker.
Good point, torque isn't just measured in ft/lbs, thanks.
.......I can’t remember working on an rg500 in the past?......😬😬😬🙈
Stop showing this engine porn! I'm out of wipes and can't clean my screen now.
^^^^2t wanker------- I don't understand the crank arrangement. with two up and two down, it's a twin with a bunch of extra parts, in as far as power to the main shaft. if you could explain why this is better than a 90 degree setup? thanks. I also didn't see what drove the rotary valves, I guess that will be apparent in the assembly portion. I REALLY am enjoying this series.
Suzuki in particular experimented with various arrangements in racing, starting in the '60s. Yamaha did the same a bit later. They both found that simultaneous ignitions were kinder to the gears between the two cranks, but even then they still take a beating, partly because they'll never be perfectly in sync.
There are also balance advantages, if you can visualise that! All the rocking couples cancel out, I think.
Now, just think, Suzuki also made a three cylinder with this general layout - effectively just removed one of the bores and heads...
Are you Guy Martin's brother?
Matt is that motor not missing thermostats?
yes it is - part 0 explains some of that.
When ridden hard, or raced, on really hot days the stock radiator is inadequate. Removing the thermostat is what some people (including me) do attempting to solve the problem. All it does it make the engine take longer to warm up. The real fix is a race radiator from Mark Dent.
They did it because the 6mm threads were fucked and instead of a sleeve or a coil they used imperial bolt and cut a thread with it
Well not on a rg500 because that would be sacrilege although I am Infact guilty of doing it on a 1.9D citroen berlingo because who gives a F%$#. Awesome stuff (the videos not the bodgeit and scarper)
Got to love buying used bikes, never know how much stuff the hamfisted goon who owned it before you has buggered up!
I'm gonna guess that the holes stripped prior to the incorrect Allen heads being installed, and that this was an "I don't want to tear this down and fix it properly" solution... (Still stupid af, but...)
The RG was a jewel of an engine and box, and some moron has butchered a classic which, in good condition, could go for over $25,000! The unit on the bench looked a bit unloved but what a disappointment to see the damage an idiot can render. I owned one in the 80s and regret ever selling it. Sure the narration isn't suitable for family viewing so send the kids to bed - many a cuss word was uttered in the workshop!
Rotary valves are driven by splines on the crankshaft ends.
So are these 4 125cc pistons ?
No, but they're 125 cylinder lol
I weep
Great stuff. Was quite expecting something nasty to reveal itself but prety dam good all round. Apart from the twat that put the wrong threaded bolts in it.
Thank fuck for Helicoils
Cus all of that fuck wich way does that cylinder go on orissa it the wrong one
Is love my single cylinder :)
I keep thinking its an RD500..
Don't let Suzuki or Yamaha hear that LOL
RGs are race bikes..RDs are sport tourers. When the power valves rotates on an RG the power increases dramatically. When the power valve rotates on an RD the sound changes a little with no noticeable change in rate of acceleration.
33:26 moped conversion kits..... i dont know any moped conversion kit that puts 2 moped engines together (i cant speel for shit)
Spell
scooterswapshop.com/products/minarelli-mxs-twin-cylinder-kit
tnx... i get smarter every day :D
The Workshop absolutely nutty I want one
Supposedly these bike's had a 2nd gear issue burr's I guess nothing major but had to be fixed
3:20 & he's already jizzed on the engine!
LMAO!
No that was issac lol
Wife cheating with the postman 😂 lucky i dont have that problem currently single 🤣
Serious question tho, howcome 4 strokes have breather pipes and 2 strokes dont ? 🤔
Because the crankcase is used as a pumping chamber. If you had a breather the fuel and air would piss out of it.
What a stupid idea burying the barrel bolts down inside with the coolant!🙄🙄🙄....
Thought this was a motorcycle channel, englishman rebuilding a weed whacker engine, seems more like a Project Farm video!
Can you do a video how to suck start a Harley Davidson
7:12 LOL
Yes it's pure porn & I want one.... but then I see the 0.5 on top of the pistons & remember how often I used to replace piston & rings (in an already oval bore) on a 125 single, oh for a heiress girlfriend.
Recent rebore then bodge threads, WTF (as young people would say... again)
I raced mine for six years all over California for six years on the stock pistons. No problems. Then I made it a 570 because I was delusional and thought I needed more power.
Ha yeah wasn't born till 1955 LOL
7.0:1
good, but do much swearing....!!!
2nd
Tried watching this with children in the room, all the swearing very unprofessional, very messy and untidy I wouldn't let you work on my lawnmower!
It's youtube dickhead.
@@thedirtyworkshop that comment proves your the dickhead
Good commentary not