New Steed in the Stable - 1977 TS185

[FastDoc]

There's gotta be some forum you can join for people who work on old Suzukis. :P

[katoranger]

http://www.suzukits.com/


That bike reminds my of the kawasaki my Dad had when I was little. It was a 100, but I don't know the model.

[katoranger]

It was one of these.

http://www.bikez.com/motorcycles/kaw..._g4tr_1972.php

[Weldangrind]

Originally Posted by katoranger

http://www.suzukits.com/


That bike reminds my of the kawasaki my Dad had when I was little. It was a 100, but I don't know the model.

Thanks for the link!

[Weldangrind]

Did a little work on the TS185 today, once the XR250S was finished. I started with Castrol Super Clean and a pressure washer, and also took the broken fenders off, along with the seat and side panels. I took the exhaust system off and heated it with a torch to burn 30 years of oil out of it. At my next opportunity, I'll clean out the carb, inspect the clutch and try to make sense of the rats nest of wires.

Here's what the bike is supposed to look like:



Here's ours the day we brought it home:



When I was draining the tank, I discovered that the tank mount is broken. It's good to have a welder.



This is just some of what I need to sort out:

[deputygene]

Great Find! I had a 73 or 4, TS 185 when I was a teen. I rode the wheels off that thing for years. Had a TS 250 later, but it was heavier than the 185.
I have been thinking about getting another for awhile. There is an 80 DS 185 on ebay right now I have been watching.

[Weldangrind]

I found a TS250 engine on CL, and the mad scientist in me wants it badly. It has just been rebuilt with a new Wiseco piston and Boyesen reed, but I think I'll just focus on this 185 engine for now.

[Weldangrind]

I spotted a good deal on new EBC friction plates on eBay, so I grabbed 'em. I'll report on the installation upon arrival.

[SpudRider]

As always, I eagerly await your updates, Weld!

Spud

[Weldangrind]

Thanks. No noteworthy pics yet, but I did remove the headlight assembly to attack the rat's nest of wiring. It's not too far gone, since most of the electrical accessories work. The front brake lever has been replaced with a MX unit, so the brake switch is missing. I'll be looking for a new one.

I'm also going to get a universal rear fender like the one Doc bought for the Dirt Rat.

I cleaned out the carb last night, and the slow jet was completely plugged. A little carb cleaner and a welding tip cleaner solved that. I just wish I could figure out what the float level should be.

[SpudRider]

Originally Posted by Weldangrind

Thanks. No noteworthy pics yet, but I did remove the headlight assembly to attack the rat's nest of wiring. It's not too far gone, since most of the electrical accessories work. The front brake lever has been replaced with a MX unit, so the brake switch is missing. I'll be looking for a new one...

You might also wish to consider installing a hydraulic brake switch.

http://www.rockymountainatvmc.com/pr...FamilyId=25925

This switch replaces the banjo bolt in the brake's master cylinder. However, you would also need to increase the length of the wires coming from this switch.

Spud

[Weldangrind]

Nothing but drums on a '77 TS185. I need to pick up a simple lever with a switch.

[SpudRider]

Originally Posted by Weldangrind

Nothing but drums on a '77 TS185. I need to pick up a simple lever with a switch.

Oops! :oops: I forgot to look closely at the front wheel.

Spud

[Weldangrind]

Made some slow progress this weekend. Took the carb off for cleaning, removed the clutch cover in preparation for installing new friction discs and removed the engine.

The carb is unlike any I've worked on. One throttle cable splits into two; one side pulls the throttle open, and the other operates the oil injector. There is another cable (the grey one in the pic) that pulls the throttle closed.





This is the top of the carb, followed by a shot of the slider down and then up. It uses a bellcrank-type mechanism to actuate the slider. It feels very precise, but heavy.







This is the slow jet before and after. No wonder it wouldn't idle.





The clutch cover is typical, but the clutch linkage isn't. I was surprised to see how clean the clutch and interior is. Kind of surprised that the clutch was slipping that badly at high RPM.







It might be that the clutch is fine, and the chain was slipping on the countershaft sprocket. You think?



I can also see that it was the shifter seal that was leaking on my driveway. I was able to get numbers off of it, so I'll grab a new seal at Precise Bearing. I might as well do the countershaft seal at the same time.



I'm not feeling any lateral or vertical play in the crankshaft, so I think we have a winner. Since I already bought the friction discs, I'm gonna soak 'em and install them, but I really need to order new sprockets and a chain.

[SpudRider]

Yikes! I've never seen a countershaft sprocket so worn! 8O

Spud