Part 2 - The Engine Rebuild

We have separation.

This was the first thing on the agenda. The engine had not been split before and after 35 years proved to be a tad tricky to get apart. However, after much patience and the purchase of a flywheel puller, it eventually came apart cleanly.

All bearings were replaced as were all oil seals. There is a blind bearing on one side for the gearbox shaft, this was a challenge to remove. Despite many discussions with experts on the Suzuki TS forum, the thing wouldn't move. However, a trip to the Roman Baths in Bath helped solve this one. See the separate post on how this was done using a homemade Lewis Bolt if it is of interest.

All bearings were replaced with Koyo bearings and a local engineering firm rebuilt the crank, rebored the cylinder and supplied the piston and rings. During the re-build many new parts were used including stainless Allen bolts throughout and most importantly, a new Suzuki NOS reed valve.

The strip down commences.

Take away curry containers are so handy.

The heart/oil pump.

More bits.

Gearbox kept in-tact for now.

Removal of old main bearings

All ready for the rebuild.

Like a work of art.

Time to re-unite the crankcase halves.

All Done.

Barrel with new piston.

Lots of new Suzuki parts including a very expensive new reed valve.

New studs for the head.

Back in the frame.