Suzuki 2 Strokes

Well after splitting the case on my 73 GT750, my water leak is right where Allen said it might be and that is at the water bypass. I know Suzuki put an o-ring on the later models, but since I have a 73 I am wondering if anyone has come up with a solution.

I would think a tube that was long to go through the top half of the case and rest on the bottom with a rubber or copper bottom would act as extra protection. Does this make sense? One thing it would be easy to replace when the copper / rubber wore out.

I may be worrying about nothing as I expect the 1194 gasket stuff probably holds the water back for 10+ years.

//Pat

I have a 72 and a 73 case to work on, and my solution is to do one of two things.

1, add JB weld onto both of the areas and then recreate an o ring groove in the lower half as on the later engines. This means carefully sanding the surfaces back to the correct level after working the JB into the shape.

2, weld the cases around the bypass hole to recreate the later style shape casting and then recreate the groove, again making it just like the cases on later bikes. Sitting the case in some water will help keep heat values down around the welded sections during the job. You will have to make sure the surfaces are 100% correct after the work or you have wasted your time.

I was looking at the following site:

http://www.practicalmachinist.com/vb/ge ... ove-87674/

Way over my head but some interesting reading on the science of milling for an o-ring.

//Pat

While a 'proper'; fix to replicate the factory change (it was introduced at frame 36198 by the way) would perhaps be the ultimate solution - the original version has typically lasted over 40 years eh ? The J I will be rebuilding at some point has the early style of case, and I don't plan to do anything more than ensure I'm careful with the sealant.