Suzuki 2 Strokes

Hi

The engine assembly on my 1972 500J has gone pretty smoothly. The transmission shafts and gear clusters were removed as units by the previous owner and don't appear to have been split into component parts. Everything went back in nicely in the cases and I was able to shift through the gears while the cases were open on the bench. I do, however, have a question regarding the transmission drive shaft.

The end of the shaft is visible in the clutch housing, however in mine the end of the shaft is not flush with the outer face of the "D" bushing, it is set back by about one millimeter. It just looks a bit odd and I don't know if this offset is correct.

The "D" bushing is installed with the "D" facing outwards and visible. Before I open up everything to check my assembly, can someone tell me if this recessed shaft is to be expected, or should the end of the shaft sit flush with the outer face of the bushing and I need to open the cases up again.

I tried to post a picture but don't seem to be able to get it uploaded; hopefully my explanation will be enough information to explain my dilemma.

Greatly appreciate any words of wisdom!

Many thanks

Andy

I would need to see pics to compare it to my T500 motor.

Post your pics to an image sharing site. I use Flickr — it’s free & easy to use.
Then include links to those pics on your posts here.

Hi Jabcb

Thanks for the advice regarding Flickr. I have uploaded a photo that hopefully shows my dilemma...

https://www.flickr.com/photos/197518690 ... ed-public/

What do you think? Odd or correct?

Any advice appreciated!

All the best

Andy

There are alignment pins in the bottom crankcase half. If you properly engaged those alignment pins with the bearings/bushings/etc, then it’s is correct.

Also, it looks the same as in my build: https://flic.kr/s/aHsm9pLh8g

Thank you Jabcb, it is great to get your confirmation that my drive shaft offset looks normal.

I enjoyed your build photos on Flickr; you made an awesome job, the bike looks like it would be a blast to ride!

All the best

Andy