Suzuki 2 Strokes

A lot goes into custom modding its all those details

isn't it just................
I've been putting these jobs off for a while now, but as I am all worked-up on my current projects, I took the time to knock them off the "to-do" list.

plugging the water passages with an old water pump body..............



using a nut and bolt and an "o" ring to prevent seepage................



pump body refitted and silicone injected into passage to thermostat housing.........

then out with the hacksaw and an old, damaged timing side casing............



and some time later........................







another 3" taken off the engine width.............



and a little bit added back on..................



but carbon fibre weighs a lot less than a block of alloy.............

not a lot today - plugged the oil galleries that feed the l/h side (where the water pump/ tacho drive gears live) using a metal putty applied from both sides.

from the outside................



and inside....................



also dispatched a spare clutch cover to a company that specialises in water-jet cutting of aluminium to have what amounts to a "full" gasket produced out of 4mm sheet. Saves me from having to do a a lot more drilling / shaping / filing

garry55 wrote:not a lot today - plugged the oil galleries that feed the l/h side (where the water pump/ tacho drive gears live) using a metal putty applied from both sides.

Ah the good old racing chewing gum trick! I wonder how many races have been fought and won thanks to a bit of putty....
Do you think it will hold permanently?

Define "Permanently" in the context of an old two stroke triple.

sportston wrote: Do you think it will hold permanently?

I have no idea - just hoping, really............

tz375 wrote:Define "Permanently" in the context of an old two stroke triple.

look what arrived today....................



...................the clutch housing

the water-jet cut clutch side casing in place............

final shaping of clutch aperture, as was last night..............




as is tonight.................




fed up of filing, me............

collected the GS input shaft and the modified clutch hub today...........



and remembered to remove the roll pins from the shaft bearings (GS gearboxes use half-ring retainers and roll pins - GT750's only use half-rings)...........





also cut the hole in the side plate for the kick start shaft...........



input shaft, clutch hub and kick start shaft in place........

tonight I have been mostly modifying the clutch pressure plate to accept a small, sealed roller bearing....



.........the purpose of which is to allow the pressure plate to rotate freely around the clutch pull shaft......



ooops! - the pressure plate doesn't fit inside the aperture ..........



did I mention previously about the final shaping of the clutch aperture? A tad prematurely, as it happens..............



more bloody filing.........but the result is worth the effort.........