XR11/73

[garry55]

thanks for that repair tip - great idea

Bit late for me now though as I am having a new gear made in aluminium.

[Suzukidave]

I think one of the UK GT members was already making the gears in aluminum .

[rngdng]

I noticed that your water-pump drive gear is cracked. I haven't posted this repair in a while, maybe someone can use it.

Lane - that is a useful tip, but would you not agree it is best to just buy a new one ? They are still available directly from Suzuki dealers everywhere on the planet other than the USA eh ?

Well, if you just have to have "new".....



Lane

[garry55]

today I thought I would fit the replacement crankcases into the frame - not as straightforward as I hoped because there are a few subtle differences between the early "J" & "K" model crankcases and the later "L" thru "A" versions. Firstly, you can't fit early barrels to later crankcases, as the later barrels have a locating dowel on 2 of the barrel-retaining studs that the early barrels aren't drilled for. This is why I decided to run with the later set of crankcases, as I am using a TR750 spec tuned barrel which is of the later type.
Firstly, I had to replicate the mods I made to get the "J" crankcases to fit, so off with the oil pump cover mounting casting.......



then remove the 2mm protrusion on the very back of the crankcase halves, which I forgot to take a picture of.

and did they fit?.........no - for some reason, the bottom r/h mounting bracket was fouling the lower crankcase. It didn't do that with the "J" cases fitted. Oh well, unbolt the lower mounting and apply some filing to the offending area........



now they'll fit

nope - whats left of the aforementioned oil pump cover mounting casting was fouling the frame bracket. As there was insufficient material left to remove from the crankcases, I sparked up the angle-grinder and lopped a section of the frame bracket off......



surely now they'll fit?...........yep



the crank is going for a full rebuild and the the crank webs pinning on Monday.
I will be collecting the Fahron-tuned, TR750 spec barrels and full set of matched pistons on Thursday and, hopefully, will deliver the rolling chassis complete with "empty" motor to my welders the week after. They will be fabricating and attaching the forward upper mounts that will complete the installation of the motor.

maybe - just maybe............

[Zunspec4]

Great project Gary , keep the photos coming.

[Suzukidave]

With the new Katana frame project i thought this one was shelved

[garry55]

Hi Dave

currently working on 4 projects - hoping to get at least 1 finished! This one got resurrected because I purchased 2 GT750 motors, one of which has the TR750-spec tuned barrels which is ideal for this bike. Before, I only had 1 motor and "borrowed" it for the Katana build.
I know I shouldn't, but now looking for a home for the third motor......................

[garry55]

Great project Gary , keep the photos coming.

thanks

hopefully I will be able to post pictures of the completed motor installation before Xmas. I'm getting quite giddy.............

[garry55]

readying the "empty" motor ready for delivering the rolling chassis + motor to my welders on Monday.

made a couple of sacrificial head gaskets at work tonight.........





these should ensure that the "empty" motor will be as near as dammit the same height as a motor assembled using the correct base and head gaskets - important as the head support brackets and mountings have to align when the rebuilt "track day" motor is fitted. Fingers crossed................

[garry55]

a whole lotta holes...........







sorted

[rngdng]

readying the "empty" motor ready for delivering the rolling chassis + motor to my welders on Monday.

made a couple of sacrificial head gaskets at work tonight.........





these should ensure that the "empty" motor will be as near as dammit the same height as a motor assembled using the correct base and head gaskets - important as the head support brackets and mountings have to align when the rebuilt "track day" motor is fitted. Fingers crossed................

I guess I missed the head modification part of the thread....nicely done as usual.


Lane

[garry55]

all ready and waiting for a trip to my welders - I feel a road trip coming on.................

[garry55]

called in on my welders today to check on the progress they have made on fabbing my front engine mounts....



none...............

[Suzukidave]

Did the welder get the job done ?

[garry55]

no Dave - I have been away on holiday / vacation (caught the blizzard in New York !) and whilst away, I have had a change of plan for the front mounts. Some re-engineering to do when I get back to work.