Thanks

Another issue. What I believe is called the kick start idler shaft is stuck in the case. Not the crank case, but the clutch/kickstart/oilpump cover (sorry, not sure on the proper term). No idea how this happened. After heating it up (the case) with a heat gun and dumping BP blaster in it I can get it to spin about 200 degrees and the shaft will move up and down about a quarter of an inch. Using some patience I will see if I can slowly work it out. My guess is the "race" in the case that the shaft rides on is not going to be in good shape, but we will see.

 

Got the shaft out, but the race is pretty messed up. I will try and clean it up a little, but my guess is I will need a new cover.

 

Got the frame and swingarm back from the coater today. Now I have to take the swingarm to have what is left of the pivot bearing races drilled out (long story).

 

I figured out why the kick start shaft would not come out. Apparently something "buggered" up the end of it. I am not sure whether a piece of metal found it way in there or what. To dent this steel it would take a large impact of some sort I would think. I inspected the gears and do not see anything that would indicate an issue. Anyway, hopefully I can just grind it back flat and clean out the race. If it does not work I will pick up a new case and shaft, I am not going to stop the rebuild for this as I can repair it with the motor in the frame if required.

 

just use emery cloth and polish the inside where the shaft rides and emery cloth the shaft end also. Then you should be okay. I have seen this happen before, many times. Never had to buy a new clutch cover or kick start shaft before. What most likely happened is the previous owner probably took it out and during the re-install didn't line it up correctly and beat it in with a hammer. Just be careful not to take much material off, it supposed to have a snug fit. it kind of pops into the case. there is no keeper clip to hold it in. so be careful.

 

The only previous owner was the Suzuki Corp. of America. My brother had it for a while and did remove the cover to replace the gasket years ago, maybe he messed it up putting it back in. Thanks for the advice.

 

Still waiting on the machine shop. In the meantime I mounted the swing arm, rear shock and A arms. Hopefully I can get the parts back and get most of the motor back together by the end of the week.

 

Good news, I got the head back and the cylinder back with a new piston and rings. Bad news, the tools forgot to order the f-ing piston pin with the piston like I asked. So, I will not be finishing the engine and getting it back together this weekend like I planned. So tired of delays over stupid stuff.

I have the front end pretty much all back together, the rear end as well. There are a couple of small things I can get done this weekend, but it will pretty much be just sit and wait for the parts......AGAIN.

 

Got the clutch, kick start, etc all back together and put on the cover. I am still waiting on the piston pin (which is driving me nuts)



Here is the head and cylinder after I got them back from the machine shop:

 

Head and cam installed.