Suzuki café racer special history

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The IMS-Smart Suzuki project started in the Autumn of 2014 with the discovery of a cannibalised Suzuki T500 engine under an upturned disused water tank in a back garden. The log book, frame log book and other parts were discovered in a nearby loft. As can be seen by the photograph, the engine is in a rather sorry state.

Having taken the decision to rebuild the motorcycle, the first step was to disassemble the engine. Various works were then undertaken: the crankshaft was reconditioned, the casings powder blasted; covers polished; cylinders re-bored, ports enlarged and polished and damage to the bearing retainers made good. The engine was reassembled with new bearings, pistons, rings and seals. The oil pump, oil lines and carburettors were refurbished. Decisions were then taken for the remainder of the customisation and the necessary parts commissioned, sourced and purchased, or designed and manufactured.

Assembly started in October 2018 and is illustrated in the following sequence of photographs. Click on any image to view a larger version.