Suzuki 2 Strokes

Has anyone ever rebushed, or bushed the cover that the shifter shaft passes through on the T or GT500 ? I ask only as my side cover is worn, and so the shifter shaft has play in the cover which, with the stock long shifter lever, means I find the gear selection to be 'imprecise'. I was thinking I could either go with a shorter shifter lever, or possibly install a bush in the side cover to remove any play.

Am I out to lunch, or has anyone else run into this same problem ? Thanks !

That may be the easiest solution Pedro

I just find that the original style long shift lever (with the blind end slitted clamp fitting) accentuates the small amount of play in the cover - it feels better with a shorter shift lever, but I wanted to keep the original part as the splines were in good shape and it hadn't been mangled. I have a spare cover I can experiment with.

I am not familiar with that case / side cover, but if there is enough surrounding material I see no reason why a sleeve / bushing wouldn't work. If you can find a piece of Nylatron, that's what I would use. It's oil impregnated nylon and is extremely wear resistant, especially in a rotational situation. My second choice would be sintered bronze available from most bearing supply houses. My third choice would be (believe it or not) plain old black carbon. Yep, that stuff is tough as a boot when used as a bearing and shows virtually no wear after years of use

Thanks Coyote - I'll check it out.

Have you tried a new stock seal in the cover? it is the same seal as on the other side of the shaft, in the engine case.

ConnerVT wrote:Have you tried a new stock seal in the cover? it is the same seal as on the other side of the shaft, in the engine case.

I'm not exactly sure how that would help as the seals are fine - it is the left side cover that is the issue - but thank you for the suggestion.

Sorry. I was thinking right side (clutch) cover.

Ian if you have the time why not go for a cover bushing as a sort of experiment, the original T500 shifter is such a long ungainly affair no wonder the gearbox shifter throw feels so far between the gears.
I had a mind to shorten one and have it rechromed so it still resembles the original ones general shape for a restoration. You'd be surprised what an inch or a little more off the end can do to overall throw and feel.

Suzsmokeyallan wrote:I had a mind to shorten one and have it rechromed so it still resembles the original ones general shape for a restoration. You'd be surprised what an inch or a little more off the end can do to overall throw and feel.

I did think about doing the same thing, but the original was in such good shape and they are now relatively rare so I decided to leave it as is. I will just get used to it I suppose.