2x stroke street tracker - project coming together slowly.

[NoRiders]

It's always a goo

Looking good, keep up the good work.......I'll have to get myself to Kempton one day.......I better go by push bike though, taking a van could be a disaster for the bank balance

It's always a good morning out IMO. And yes....you'll need a van haha!
I got the impression you lived nearby?

 

[lchris21]

It's always a goo

It's always a good morning out IMO. And yes....you'll need a van haha!
I got the impression you lived nearby?

No, miles away, but always fancied a nose around? Thing is like most things these days with freely available valuations of stuff, I doubt there'd be much in the way of barn finds or rare items without some over inflated asking price

 

[NoRiders]

No, miles away, but always fancied a nose around? Thing is like most things these days with freely available valuations of stuff, I doubt there'd be much in the way of barn finds or rare items without some over inflated asking price

I see quite a few bikes for sale, complete in good cond and many many projects....mostly Brit bikes but a good many Japs/Italian and a few odd balls too.
the ting aboutvents like these is you never know what you'll find.....part fo the fun. Go with a bank roll and you never know...

 

[NoRiders]

The GT200 engine is with my neighbour to rebuild...popping round tonight to go through the parts and process....can't wait.

In other news I found a jacket I'd wear while riding the bloody thing...official Suzuki, nice quality and fits good too. £25 of our English pounds.

 

[NoRiders]

Update: Engine rebuild under way....problem!! The SB200 kickstart crank is different to the GT200 electric start crank......the drive end spigot is shorter on the SB200 by approx 8mm so will not accomodate the starter dog gear as the crank needs to be slightly longer.....bugger.

I'll need to have the GT crank rebuilt with new seals n bearings......I may as well keep the SB crank I've already had done.....as I plan to rebuild the SB engine as a spare....although not it won't be a like for like swap, I'll at least give me a working engine if the GT blows up.

Not a major major issue but it's more expense and time added......still, could be worse.

The cases are full of crud so this rebuild was just in time I reckon.

 

[NoRiders]

Update: Engine rebuild under way....problem!! The SB200 kickstart crank is different to the GT200 electric start crank......the drive end spigot is shorter on the SB200 by approx 8mm so will not accomodate the starter dog gear as the crank needs to be slightly longer.....bugger.

I'll need to have the GT crank rebuilt with new seals n bearings......I may as well keep the SB crank I've already had done.....as I plan to rebuild the SB engine as a spare....although not it won't be a like for like swap, I'll at least give me a working engine if the GT blows up.

Not a major major issue but it's more expense and time added......still, could be worse.

The cases are full of crud so this rebuild was just in time I reckon.

A good news follow up ....I'd arranged quotes for new bearing/seals and spoken to the fella, (Gardias Engineering, Witney Oxon), who said drop it in and he'll be happy to do it asap.

However, my neighbour, Andy has fitted the SB crank and the extended spigot on the GT crank holds the tacho drive gear cog.....as I'm not using a tacho I'm happy to dispense of that facility......I can always have the GT crank rebuilt at some stage as I do plan to rebuild the SB200 lump as a spare.

So, good news me thinks?

 

[NoRiders]

Progress on the engine rebuild....starter clutch was missing a few parts...so a new repro starter clutch repair kit order, arrived and delivered to Andy.

Anyone used the Tourmax kit before?


Cases and internal parts all cleaned today ready for the final assembly....

 

[teazer]

You're making progress which is good in teh flooded UK. Those parts look like they would fit many different starter clutches.

 

[NoRiders]

You're making progress which is good in teh flooded UK. Those parts look like they would fit many different starter clutches.

Yeah...feels slow slow slow at the mo....but I'm hoping a successful rebuild will set me right back on it.
PS We've had a bit of rain but almost zero flooding, beyond seasonal norms, in our neck of the woods. Thanks for checking in.

 

[NoRiders]

Engine oil seals (gear change, final drive and clutch rod) ordered from Wemoto UK. Somewhere in the dim n distant past I recall I may have ordered these seals in previously.....mind you I was very, very drunk at the time

These guys have been very good as I've used them almost exclusively for Suzuki parts. Keen pricing, good stock and fast delivery.

Link: https://www.wemoto.com/

 

[NoRiders]

Seals are in!
But, the Athena complete engine gasket kit excludes the generator casing gasket....WTF??!! Not available from all the UK suppliers (that I know of) and ebay.

We can tap one out or use RGV sparingly. Just annoying that a kit falls short....like we're not going to remove the stator casing at all.

Cleaning and painting the side case and cleaning the barrel in readiness for the stitch up.

 

[NoRiders]

Who wants to see a picture of a halfway built engine?...no pushing at the back!

I painted the chain/oil pump case but will fit that later when I've sourced new oil delivery pipes and a feed pipe too.

Any pointers or recommendations on the type/make* of oil delivery pipe I should be looking for?

* I'll try my usual supplier.

I'll probs leave the other side cases eu naturelle as I kinda like the used but clean look....this bike is meant to be a functioning comp bike after all...and comp bikes are clean but not highly polished or preened.

We used Wellseal on the gen case as a gasket wasn't available and making one didn't make sense to be honest.

I'll now have to fashion the engine mounts and sort the exhaust out.

 

[NoRiders]

Well, this morning I got THE call........engine build is complete...yay!!

 

[NoRiders]

Boom...

The observant will notice the plugged tacho drive outlet.....SB200 cranks don't have the capacity to accommodate the tacho gear cog......I'd not planned to run a tacho so no worries.

 

[Pete12]

Wow, that looks great.

 

[NoRiders]

Wow, that looks great.

Thankee...pretty chuffed to be honest, Andy did a thorough job....found two issues, apart from the crank business, and sorted them. Kickstart mechanism wasn't installed correctly, and would never have worked....also, the centrifugal clutch parts were missing...so the starter wouldn't have worked either!!
His attention to detail, especially as he hadn't ever worked on a GT200 before, his work ethos saw it come good, I admire that as I'm a bit more haphazard and not as methodical as I'd like to be.

 

[NoRiders]

So, in isolation and after a personal recharge, I ventured back into the garage....swiping away the cobwebs I spied the Suzonda project sitting forlorn and neglected.
So I fashioned a pair of 3mm allow forward upper engine mounts, since been advised they are too thin...4-5mm minimum which is a bugger to be honest....might make them out of steel instead.

Rear axle spacer finally the correct width/length and the rear end tightens up nicely, the split-pin hole lines up with the castle nut so all's good.
Just the rear brake torque arm to make now.

 

[teazer]

Looking good.

 

[NoRiders]

Materials ordered.....2.5mm & 3mm box section to make brake torque arm and lower engine mounts. M10 threading for torque arm, and 3mm flat steel bar for the forward upper engine mounts....in place of the alloy ones.

I need to get my mojo back and this is helping....

 

[NoRiders]

While I await incoming parts (reverse operation rear brake master cylinder and 30x50mm steel box section) I was itching to get something positive done!!

so, I installed the tank front mount, which consisted of a length of M8 threading, through a hole I drilled in and through the headstock gusset with two cut down common white rubber door stops to act as shock rubbers.

Turned out OK I reckon....tank aligns well enough with the seat unit and fork/headstock/yoke and I hope to have got the tank inclination and angle right too.

The rear mount will be a block of flexi rubber, possibly a car exhaust mount rubber with a bit of squish in it and the rear of the tank held down using thick rubber bands (cut down inner tube?)....quick release

. I'll have to have a scrounge around my local exhaust place...once the isolation thingy is over.

Thankx for checking in