Hello everyone, recent rescue of a C2, mostly complete with the exception of salvageable plastic. I have a list of questions a mile long but I will not be overbearing as a noob and ask them all at once
I have the bike torn down and in several sub-assemblies. The cylinder is on std bore as close as I can tell. I heard the bike run when I bought it. Upon teardown, the crank nut (rh side) was 4-5 turns from coming off, all three of the bearing retainer screws were broken off. It had a new gasket on the clutch side. Here are the first questions...
1) the main bearing on the right side is standing proud about 1.3mm from being flush with the case bore, shouldn't the new bearing I install be flush? The retainer plate is missing so I'm going to make three separate retainers to go under the screws. I have a Clymer manual but it was made with a 125 as the focus as far as reference pictures go, a lot of the pictures are not really what I am looking at.
2) While the cases are split, of course the trans shift dogs dropped out. Going by the Clymer manual the shift drum is supposed to be in the neutral position to line everything up. I have been able to get the trans in neutral, but I'm not sure it is shifting correctly. I can turn the input shaft and hold the counter shaft so I assume that is neutral. How do I determine all is well? It is difficult to hold the shift shaft in place and shift up/down on the bench. Seems like it takes a lot of effort to change gears and I'm not positive it shifts through the entire range.
3) What have you guys used for airboxes? Every one I find has the back side broken out like the one I have.
I have looked at every page on the Suzuki specific page and the Tech page...lots of really good info there!
Thanks for your help, and I'm super pumped to be a part of this great group! More questions to follow I'm sure.
Kenny