Almost finished

Crank finally back in place..

After a lot of head scratching and time, the crank arrived today from Bernd Braun, a suzuki and 2-stroke crank specialist that fixed the crank for me.. I was not able to line up the crank accurately on my own..

But bernd called me a Few days after he recieved the crank and told me that one of the crank webs in the middle was damaged too much to use and it had to be replaced.. If the damage was there before or after i tried press the crank back i dont know. But now its all done and the engine assembly can begin!

I would highly recommend bernd braun, the finish on his job i amazing and the price is very fair. This is just not something worth doing yourself..

Here is a link to his webpage: http://www.crankup.de/

New master cylinder

Duo to the new 'ace' clip-on's wich is a bit shorter than the original handlebar, i am no longer able to use the original master cylinder. It is just too long to fit. I did some research on google to find an older, cheap, common suzuki item that was smaller in size. I ended up with this 'Nissin' unit from '85 katana GS650. It is much shorter than GT one. I polished it to make it look like new.. Not bad for 35 bucks. I only needed a new banjo bolt, since the nissin master cylinder has M10x1,25 thread and not 10x1 fine thread in the suzuki gt unit.

Tank finished

Today i went down to were i work and finished the tank. When i came home i quickly tried the tank in the frame and it was a tight fit, but still perfect. I think that this tank holds just as much oil as the original plastic one. About 0,4 gallon.

The lid is made of brass. To avoid vacuum in the tank i made a 2mm hole in it, and then cut a round piece of 2mm neoprene rubber and drilled 3 holes in that. It works fine and prevents dirt inside the tank

A pneumatic plastic hose acts as an oil level guide

Ally Oil tank

I've been working a bit on the custom aluminum oil tank.. I had to make this homemade tank to get those big original plastic sidecovers off. Instead of that, i want flat aluminum plates with a big number on..

The tank is made from 1,5mm aluminum sheet.. The thinnest i can weld safely with the TIG welder