A trial assemble of the gears.
a coating of sealant.
Then the actual assembly with the bottom bolts
And then the top bolts
After much ado the crankcases are assembled followed by the kickstart pawl assembly!! BEWARE when assembling the kickstart pawl it is VERY easy for it to slip and spring out (shaft on left in photo below). Not a major problem BUT the spring is ideally sized to slip through one of the oil tranfer holes and end up in the gearbox!!!
So if this happens (against all odds) you need to split the crankcase again and reassemble. It could never happen twice?!?!
Clutch assembly followed and was simple enough except that there is a deviation from any line drawings I have found so far in that the shaft does not have a bush but is machined to the larger diameter and then has a step as visible above. This means no thrust washer to fit above the bearing but there is a thicker thrust washer after the outel clutch casting is installed.
Spragging the clutch to allow torquing up the locating nut is a pain but the addition of a metal shaft to one of the crankcase holes lets you lock the assembly better although the complete engine will then try to rotate and needs to be held.
Found myself to be short of both washers which should be above and below the two diameter kickstart gear so that has brought me to a halt again.
Next key item will be assembly of the final parts to allow the RH cover to be installed and then the cylinder heads.
This means it's time to get the cylinders re-bored. A quick internet search has identifeid a couple of possibilities locally including a company in Guisborough who will do the re-bore FOC if they supply the pistons.
I'll call for pricing tomorrow!
On the line drawing front I have managed to get the old fische printed and scanned so I am working to produce the set of drawings with part details and references to be posted when completed. Discoveries today make me think the engine is more likely a C (1978) rather than a B (1977) and that there are some differences not shown in any documents I have. If anyone knows of any later fisches than the April 1979 release for GT250 A,B fische that I have please let me know.
im getting ready to tear into my 19723 gt250!
ReplyDeletemy GT250 ( purchased from tip) has a cracked crank case, probably caused by the previous owner falling off,due to the loose swing arm ( badly worn bushes) so if u come across a set of cases upper and lower, send em to me' (a bit hard to find in Australia) nice to see ur pics, and read ur problems, I have a better understanding of what I'm about to do,I gota strip it to fix it..
ReplyDeletelast rebuild i did was a GT185, sum 28 years ago,
Hello, I'm from germany and owner of a GT 250...where do you got all this technical drawings? Suzuki of Germany is not able to deliver any information about the GT 250. Do you have a scan of these?
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