XR11/73

[Suzukidave]

A lot goes into custom modding its all those details

[garry55]

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.

[garry55]

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.........

[garry55]

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.............

[garry55]

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

[sportston]

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?

[tz375]

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

[garry55]

Do you think it will hold permanently?

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

[garry55]

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

[garry55]

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



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

[garry55]

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

[garry55]

[garry55]

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




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




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

[garry55]

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........

[garry55]

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.........