The Almost-Cursed Suzuki RE5: Reviving a Piece of Motorcycle History
In 1975, the world witnessed the unveiling of the Suzuki RE5, a motorcycle so ahead of its time that the company had to redesign it just a year later before ceasing its production. Dubbed “the bike that almost killed Suzuki,” the RE5 is one of the most complex motorcycles ever built by the Japanese manufacturer. Despite its complicated design and the challenges of restoration, enthusiasts like Max are determined to keep its legacy alive.
Earlier this year, during a swap meet, I crossed paths with Max, who owns two RE5 bikes. He rescued these machines from a barn, meticulously went through them, and successfully got them running. With one of Max's RE5 models as our project for the day, we aimed to achieve a functioning motorcycle by the end of our repair session. However, it was clear we had our work cut out for us.
Starting at the Front: A Complex Tangle of Wires and Components
Upon assessment of the front of the bike, the first thing that caught my eye was the chaotic arrangement of wires. Max pointed out that many of the signals were not properly hooked up, alongside issues like a non-functional front brake and worn-out tires. Despite the bike's decrepit state, the chrome fender shone under the sun, hinting at its once-glorious past.
One innovative feature of the RE5 is its futuristic design elements, such as the bike's “globe” signals, which can be quite costly to replace. Max explained that the RE5 was impressive for its time, featuring an unusual oil cooling system, and a water-cooled rotary engine that was a departure from traditional motorcycles.
The technical intricacies of the rotary engine, developed from the Wankel design, require careful maintenance and a unique approach to restoration. Understanding how the engine worked was crucial for us to move forward with our project, which meant diving deep into the mechanics.
Mechanics of the RE5: Racing Against Time
As we moved deeper into the bike’s structure, every turn revealed new challenges. The absence of a functional clutch, the complex carburetor setup with multiple throttle cables, and the state of the electrical system raised numerous red flags. Max and I realized early on that we’d have to be highly meticulous in going through all components—especially the fuel and electrical systems, which had previously caused issues for the bike’s operation.
While Max focused on cleaning and reassembling the carburetor, I took on the daunting task of troubleshooting the electrical wiring. It quickly became clear that the wiring was a jumbled mess, likely causing many of the bike's performance issues. Our goal was to create a streamlined system capable of delivering power where needed, avoiding any tangled wire disaster.
Turning the Corroded into the Functional
With the carburetor cleaned and reattached, and Max’s mechanical prowess at play, we moved onto the other components. We checked the transmission fluid and coolant systems - crucial elements that would determine whether the bike could operate at all. Even with multiple setbacks, including a stubborn fuel leak that came back to haunt us post-assembly, we remained hopeful.
This RE5 wasn’t just any motorcycle; it was a piece of engineering history that few still appreciated. Getting it to run was both a challenge and an honor.
The Moment of Truth: Starting the RE5
With a fresh battery installed and careful attention to the fuel systems, the day culminated in a collective breath as Max and I took turns pressing the starter. The electric motor turned over, but strange sounds hinted at complications within the engine. Despite this, the unmistakable rumble of the RE5 filled the air, one of the sweetest sounds to a motorcycle enthusiast’s ears.
However, as the motor began to run, we discovered that the noise was likely indicative of an internal issue. Our joy quickly mixed with concern as we realized that the rotary engine might be struggling more than we originally thought.
Winding Down: A Triumph of Effort
Despite yielding some triumphs through perseverance—such as getting the engine to crank and revealing a promising level of compression—the day ended with a twinge of disappointment. The RE5 would need further troubleshooting, given the noise concerns and issues with various components.
Yet, the journey was far from wasted. Participating in the restoration of such a technologically fascinating bike opened our eyes to the engineering behind it. As the sun began to set, Max and I reflected on our efforts that day between networked wires and engine parts, embodying the true spirit of amateur mechanics.
The Suzuki RE5 may arguably be one of the most complicated motorcycles to work on, but it's also a unique piece of history. Enthusiasts like Max are integral in keeping the memory of such innovative machines alive. Our quest reminded us that, while the road to restoration can be littered with bumps and leaks, it's also filled with camaraderie, learning, and immense satisfaction in reviving a piece of automotive art. The next chapter of our RE5’s story awaits, and with the lessons learned, we’re more prepared than ever to tackle its challenges head-on.
Part 1/9:
The Almost-Cursed Suzuki RE5: Reviving a Piece of Motorcycle History
In 1975, the world witnessed the unveiling of the Suzuki RE5, a motorcycle so ahead of its time that the company had to redesign it just a year later before ceasing its production. Dubbed “the bike that almost killed Suzuki,” the RE5 is one of the most complex motorcycles ever built by the Japanese manufacturer. Despite its complicated design and the challenges of restoration, enthusiasts like Max are determined to keep its legacy alive.
Meet Max: The RE5 Enthusiast
Part 2/9:
Earlier this year, during a swap meet, I crossed paths with Max, who owns two RE5 bikes. He rescued these machines from a barn, meticulously went through them, and successfully got them running. With one of Max's RE5 models as our project for the day, we aimed to achieve a functioning motorcycle by the end of our repair session. However, it was clear we had our work cut out for us.
Starting at the Front: A Complex Tangle of Wires and Components
Part 3/9:
Upon assessment of the front of the bike, the first thing that caught my eye was the chaotic arrangement of wires. Max pointed out that many of the signals were not properly hooked up, alongside issues like a non-functional front brake and worn-out tires. Despite the bike's decrepit state, the chrome fender shone under the sun, hinting at its once-glorious past.
One innovative feature of the RE5 is its futuristic design elements, such as the bike's “globe” signals, which can be quite costly to replace. Max explained that the RE5 was impressive for its time, featuring an unusual oil cooling system, and a water-cooled rotary engine that was a departure from traditional motorcycles.
Part 4/9:
The technical intricacies of the rotary engine, developed from the Wankel design, require careful maintenance and a unique approach to restoration. Understanding how the engine worked was crucial for us to move forward with our project, which meant diving deep into the mechanics.
Mechanics of the RE5: Racing Against Time
As we moved deeper into the bike’s structure, every turn revealed new challenges. The absence of a functional clutch, the complex carburetor setup with multiple throttle cables, and the state of the electrical system raised numerous red flags. Max and I realized early on that we’d have to be highly meticulous in going through all components—especially the fuel and electrical systems, which had previously caused issues for the bike’s operation.
Part 5/9:
While Max focused on cleaning and reassembling the carburetor, I took on the daunting task of troubleshooting the electrical wiring. It quickly became clear that the wiring was a jumbled mess, likely causing many of the bike's performance issues. Our goal was to create a streamlined system capable of delivering power where needed, avoiding any tangled wire disaster.
Turning the Corroded into the Functional
With the carburetor cleaned and reattached, and Max’s mechanical prowess at play, we moved onto the other components. We checked the transmission fluid and coolant systems - crucial elements that would determine whether the bike could operate at all. Even with multiple setbacks, including a stubborn fuel leak that came back to haunt us post-assembly, we remained hopeful.
Part 6/9:
This RE5 wasn’t just any motorcycle; it was a piece of engineering history that few still appreciated. Getting it to run was both a challenge and an honor.
The Moment of Truth: Starting the RE5
With a fresh battery installed and careful attention to the fuel systems, the day culminated in a collective breath as Max and I took turns pressing the starter. The electric motor turned over, but strange sounds hinted at complications within the engine. Despite this, the unmistakable rumble of the RE5 filled the air, one of the sweetest sounds to a motorcycle enthusiast’s ears.
Part 7/9:
However, as the motor began to run, we discovered that the noise was likely indicative of an internal issue. Our joy quickly mixed with concern as we realized that the rotary engine might be struggling more than we originally thought.
Winding Down: A Triumph of Effort
Despite yielding some triumphs through perseverance—such as getting the engine to crank and revealing a promising level of compression—the day ended with a twinge of disappointment. The RE5 would need further troubleshooting, given the noise concerns and issues with various components.
Part 8/9:
Yet, the journey was far from wasted. Participating in the restoration of such a technologically fascinating bike opened our eyes to the engineering behind it. As the sun began to set, Max and I reflected on our efforts that day between networked wires and engine parts, embodying the true spirit of amateur mechanics.
Conclusion: Preserving the Past
Part 9/9:
The Suzuki RE5 may arguably be one of the most complicated motorcycles to work on, but it's also a unique piece of history. Enthusiasts like Max are integral in keeping the memory of such innovative machines alive. Our quest reminded us that, while the road to restoration can be littered with bumps and leaks, it's also filled with camaraderie, learning, and immense satisfaction in reviving a piece of automotive art. The next chapter of our RE5’s story awaits, and with the lessons learned, we’re more prepared than ever to tackle its challenges head-on.