Suzuki 2 Strokes

Hi,
I just registered here. I'm Dutch, 52 years old and I currently live again in Germany after having spent the last 3 years in the South of France.
Been riding bikes since the age of 17, First bike was a GS550 and soon thereafter I bought a crappy GT750 that had spent 10 years in a pig sty
with the cylinder head off. Got if for 100Dutch Guilders. Same seller sold me a T350 too. Ages later I got several RD350 YPVS and a KR1S.
That last one nearly cost me my licence, as I got caught doing 110miles on a 40mph road. Sold it and got a TL1000R as I tried to stay away from 2strokes.

Upon returning from France I now got hold of a GT185, which doesn't look too bad regarding the 650euros I paid for it. Last week I found a lonely GT380 engine
that I will overhaul and as I don't have the funds to create a whole GT380 I intend to fit it in a slightly more modern rolling chassis I got....

Best regards,
Charles

Welcome and sounds like you’ll fit in just fine here. You’ve had some nice bikes.

Welcome Charles, sounds like an interesting project.

Welcome! I'd love to see a GT380 lump in a more modern frame. Ambitious! Don't forget to post pics when you get around to it.

Hi Charles and welcome to the forum great selection of bikes! You have several good suppliers of parts in your country. If you send an email to gtreiner1@aol.com ask for a parts list he is very well stocked.

Thanks everyone!

Yes, I will post pics as soon as I start. I already put the engine in the chassis to see how it fits and
it does surprisingly well.Need to fabricate proper mountings of course. The rolling chassis is nothing fancy,
I guess you all will roll your eyes how I could use such a daft bike as a donor.... My answer is it's what I got available..

Just got myself another engine as the one I bought first missed the oil pump, oil feed pipes
and the sprocket cover. Stumbled upon a very neglected looking engine not too far from here
and got it for 200€. So now I got at least all parts to make one decent engine.

Started disassembling this neglected engine. Does not look too bad, will post some pics in the appropriate section later.
Got now the problem that I do not know yet how to take the primary gear off the crank. Is it fixed with a woodruff key? The original 1974 manual I just
bought just says take it off.Will ask in the repair section....

Best regards,
Charles

GTandcbr wrote:Hi Charles and welcome to the forum great selection of bikes! You have several good suppliers of parts in your country. If you send an email to gtreiner1@aol.com ask for a parts list he is very well stocked.

Thanks, I heard from Reiner before. I don't think I will be needing many parts, as it will be just the engine and carbs that will be GT380,
everything else won't be. Pipes will be from Higgspeed and I intend to fit a race ignition from Electrex.

Best regards,
Charles

Yes Charles primary drive is held in place with woodruff key

GTandcbr wrote:Yes Charles primary drive is held in place with woodruff key

Thanks and how would you remove this one?

Best regards,
Charles

The primary gear is held on the crank by a nut. Underneath the nut the gear has a slot with the woodruff key inside. Remove the nut and slide out the key

GTandcbr wrote:The primary gear is held on the crank by a nut. Underneath the nut the gear has a slot with the woodruff key inside. Remove the nut and slide out the key

Thanks! I have already removed the nut and tried poking in this slot with no result. I'll have another go this evening.

The key is half moon so it will not just slide out, until the gear is removed.

karl pa wrote:The key is half moon so it will not just slide out, until the gear is removed.

So how would you proceed? Both gears don't move at all with the key in place?

I don't believe the gear is pressed on, you should be able to wiggle loose, maybe a little help from screw driver or puller. Why do you want to take these gears off if I can ask?

karl pa wrote:I don't believe the gear is pressed on, you should be able to wiggle loose, maybe a little help from screw driver or puller. Why do you want to take these gears off if I can ask?

I want the crank to be rebuild, just as a precaution. I understand for the rebuilder these gears need to be removed? Was thinking of using PJME? Some of you must have experience with them?

I tried to remove them carefully with a rubber mallet, but they don't move at all... All my pullers won't fit properly.. should I apply some heat?

Thanks,
Charles