I love the look of that 350!
I can’t wait to paint it another color haha. I really dislike the British racing green.
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They! followed me home, I swear.
- Thread starter WideAWAKE
- Start date
I can’t wait to paint it another color haha. I really dislike the British racing green.
Not yet but it is on my list of things to try and get to this next week.
We just had another baby about 7 weeks ago and he’s really cramping my style haha.
I’ve had a long over due surfboard I’ve been building for a friend and a big landscape project from last year I’m trying to finish (I had to stop in the winter when the rain came and brought with it the weeds!).
I have been working on some odds and ends with the bike and pretty much have all the parts I need, just need to get it together.
Sooo… it’s still ugly haha.
I did manage to get the frame all welded up (I’ll get some pics) and I am taking it to get sand blasted tomorrow so it’s ready for paint.
I had had to send my cylinder set out to get bored and here in lies the ugly…
The guy does the work and THEN tells me, “hey I had to go over a little to get it all to clean up”
Well his “little over” was a .012 piston to wall clearance - UGLY.
My issue now, a bigger piston can not be found, so my options are to find a new barrel (there is one on eBay at $250 once it’s to my door) or run it and I’m guessing have some piston slap and then comeback to it and address it again when it wares down.
It’s a 2 year only motor so parts are a little scares.
This one is certainly an uphill battle.
I did manage to get the frame all welded up (I’ll get some pics) and I am taking it to get sand blasted tomorrow so it’s ready for paint.
I had had to send my cylinder set out to get bored and here in lies the ugly…
The guy does the work and THEN tells me, “hey I had to go over a little to get it all to clean up”
Well his “little over” was a .012 piston to wall clearance - UGLY.
My issue now, a bigger piston can not be found, so my options are to find a new barrel (there is one on eBay at $250 once it’s to my door) or run it and I’m guessing have some piston slap and then comeback to it and address it again when it wares down.
It’s a 2 year only motor so parts are a little scares.
This one is certainly an uphill battle.
I’ve always admired people that take on the challenge of restoring rare machines, it requires a lot of creativity and being able to machine parts certainly helps. I’m afraid it’s outside of my skill set. I hope you get it figured out.
I’ve always admired people that take on the challenge of restoring rare machines, it requires a lot of creativity and being able to machine parts certainly helps. I’m afraid it’s outside of my skill set. I hope you get it figured out.
I’ve come to the conclusion that since I have all the parts ready to go, I’ll build the bike complete, start it and see what it sounds like. Worst case it’s a loud noticeable slap, I’ll pull the top end and swap it. It’s very easy access and just a few head bolts and it slips right off. Would only take about an hour if you had the new barrel and piston ready to go. Seems Suzuki designed it to be rebuilt trail side haha.
Piano piano as the Italians would say
.12 mm or inches?
And when I say “piston to wall clearance” I am refuting to the overall bore. My verbiage may have been off there. Saying wall instead of bore.
Meaning the bore measure .012 bigger than the cylinder, which is about 3x spec…. Ugly.
Meaning the bore measure .012 bigger than the cylinder, which is about 3x spec…. Ugly.
Not to rain on your parade, but....
Our XS' have about a 75mm bore with a skirt clearance of about .002".... pretty typical for that size bore. Your little 250 is about 70mm (I'm guessin'....) so I'd expect a skirt clearance of about that or slightly less. Say .0015 to .002". You're almost 10 times that.
That would make shattering the skirts a real possibility. If it were me, I don't think I'd chance it.
Sage advice.Not to rain on your parade, but....
Our XS' have about a 75mm bore with a skirt clearance of about .002".... pretty typical for that size bore. Your little 250 is about 70mm (I'm guessin'....) so I'd expect a skirt clearance of about that or slightly less. Say .0015 to .002". You're almost 10 times that.
That would make shattering the skirts a real possibility. If it were me, I don't think I'd chance it.
Not to rain on your parade, but....
Our XS' have about a 75mm bore with a skirt clearance of about .002".... pretty typical for that size bore. Your little 250 is about 70mm (I'm guessin'....) so I'd expect a skirt clearance of about that or slightly less. Say .0015 to .002". You're almost 10 times that.
That would make shattering the skirts a real possibility. If it were me, I don't think I'd chance it.
The Suzuki book calls for .0045 max.
This parade has been in the rain for quite some time haha.
Suppose I’ll finish the motor less the head, paint and assemble and see where I’m at.
Was trying to keep the whole project under 1k ( including the bike) but it is what it is.
It’s such a nice looking bike and very uncommon. I can certainly understand wanting to rescue it. I know next to nothing about engine building, but I was wondering if a company such as Wiseco would have any custom offerings?
Quite possibly.
There is a .05 over barrel and piston for sale on eBay at the moment for $250.
I’d guess going the route of a custom piston/rings and then having to rebore would probably get me in the same price range.
Gonna keep my eyes open for a decent used barrel. My piston and rings are nos.
If I can find one cheap enough then a rebore is all that’s needed.
That's how I'd play it.
Except I'd hold out for a standard bore barrel. Leaves more room for oversizing rather than starting a .5 over.
Bored with piston and rings is a smokin' deal at $250. Better suck it up....
some goodish and some more bad haha.
I ended up biting the bullet on the cylinder. Sent the seller a message and he gave me a deal ($190 to my door).
Part showed up and while it was a standard bore with an NOS piston, the skirt had a .005 taper and the piston didn’t go through the bore! Can’t catch a break!!! Haha.
I was able to stick it in the mill and hone it to the correct size. Soo while it took some work, I now have a standard bore cylinder with an NOS piston and rings.
Also got my frame blasted for $50 - primed it with some 2k epoxy (rattle can) and shot it with some 2k black topcoat (rattle can).
Now I can start rebuilding the motor.
And on a side note - on the frame, I just ended up running a bead of weld on the crack, grinding it flush. Stuck it on its side and stood on it and jumped a few times, no cracks. Time will tell. I’ll take it off a few jumps and see what she does. Worst case, fix again and add some bracing.
I ended up biting the bullet on the cylinder. Sent the seller a message and he gave me a deal ($190 to my door).
Part showed up and while it was a standard bore with an NOS piston, the skirt had a .005 taper and the piston didn’t go through the bore! Can’t catch a break!!! Haha.
I was able to stick it in the mill and hone it to the correct size. Soo while it took some work, I now have a standard bore cylinder with an NOS piston and rings.
Also got my frame blasted for $50 - primed it with some 2k epoxy (rattle can) and shot it with some 2k black topcoat (rattle can).
Now I can start rebuilding the motor.
And on a side note - on the frame, I just ended up running a bead of weld on the crack, grinding it flush. Stuck it on its side and stood on it and jumped a few times, no cracks. Time will tell. I’ll take it off a few jumps and see what she does. Worst case, fix again and add some bracing.
For anyone interested.
Definitely needs the three minute shake that is recommended and intermittent shakes.
But for what it is, a 2k rattle can without a canister, it works pretty good. And easy touch up if ever needed.
Frame came out beautiful! Congratulations on getting your motor squared away. Can’t wait to see your progress! 
