Suzuki 2 Strokes

so ups will be bringing my crank from Mr. Bune today. I think i am all ready to put the cases toghether. Any last minute tips before install? O ring for water jacket is ready. kickstart assembly is lined up with hash marks. tranny is in lol. all bearing retaining rings are installed. copper washer on case bolt 13...check. one question, the two c rings that go into the grooves in the crank bearing area-the one concave/convex one is discarded because of the new style crank seal correct? what about the other one just to the left of that one...does that one stay? any other checklist items i am forgetting?

There should be an anti-rotation pin for each bearing. That large C washer was replaced with a seal with steel locating flange as you said. C clips/half moon clips on all 4 transmission bearings, plus large C ring for the main bearing to the left of the primary gear

And don't forget the water pump drive shaft plus its c ring and half round peg.

check oh ya almost forgot about the tach drive shaft

im not supposed to put any sealant of any kind on the new seals before install? ive read a few posts about using 3 bond on the lips to keep them from spinning? or do i need to oil them first?

No oil or sealant on the outside. A small amount of 3 Bond will ooze out from the cases and that's enough.

I always oil the seals with the crank sitting in the case half.

Follow torque sequence... don't over torque ... put fingers in rod small end for example and max sure crank spins without any binding through out 360 degree is a good idea in general. have a had a few bind a little and usually due the fact I buggered up torque amount- sequence only. Make sure the threads in case are OK... may need to chase with tap if any bolt was oxidized on threads when removed.

Wow fresh crank! Your now heading in the back together direction with your project: closer and closer to Vroom Vroom time!

thanks guys! i got the crank into the lower case. it was kind of difficult to get all the seal lips and bearing dowel pins lined up, but i got it in. the left side crank seal was a bit tight trying to squeeze into the groove in lower case and did not want to go all the way in. i oiled the lip of it, and then tightened down the upper case with a few bolts, it seemed to have snugged into the groove better. STUPID QUESTION...is it easier to install clutch basket before assembling case halves? also, i assume bill bune oiled the crank bearings during assembly. should i oil them more before assembly? its gonna be tough to oil stuff and also keep mating surfaces clean for 3 bond sealant.

Clutch is easy to fit with cases assembled. SLide basket over the input shaft and then slide the center bearing into place. There is no other way that I know of.

I usually put the bottom end in the frame and then add pistons, barrels and head and clutch and side covers. Arguably it's easier to fully assemble the motor and put it on its side and lower the frame over the complete motor.

For me, lifting a complete 180 pound motor is not going to happen, so I assemble it in place.

I am working on a 1971 T500R and I have noticed the the torque sequence on the service manual (1969 T500 II)doesn't match the number sequence cast in the crankcase. Any ideas? Perhaps Suzuki changed the sequence on the R model?

Assume the bearings (and seals) are unoiled.
Too much is not a bad thing - not enough is very expensive.