Frame repair……..

[Smallkat]

Looking really good.

[tigcraft]

I think I’ve got an idea why my bike was in the fooooked condition it was in …..
It might have gone through this sort of system and that answers the rear frame being bent.

[tigcraft]

It’s coming together although it’ll show the front up…

[tigcraft]

Old Yorkshire habits die hard as I’ve got my old 2011 tyres on it from another bike of mine swapped before it went into storage . Although I’ve lashed out and bought a new rear disc and also a chain n sprocket set all to find my front sprocket drive shaft has shagged splines!

[Uncle Bob]

The splines on the output shaft look quite worn. That must be a Suzuki thing, I had the same on the X7 I have. I investigated repairs etc (with the usual conflicting opinions on that) and there were lots of (in some cases as bad) used ones at ridiculous money but eventually got a good gearbox from Germany for reasonable price (via Lex in Holland).

Getting a used 250 Katana output shaft wouldn't be easy... Just wondered if you had a (magic maker!) fix, or just put the sprocket on and see?

This is what mine looked like:

[tigcraft]

That’s just as bad as mine! Mine I’m guessing was original front sprocket as it had the oem style rubber on it. All I’m going to do in the is case is put two welds on it which I can break when needed. The magic tool in this case is a snap on mini mig 180! on the flip side it can last another ten years if looked after and another sprocket set carefully fitted again at a later date.

[Smallkat]

Those splines are definitely a Suzuki weak spot. It's bloody annoying on my X7. I have a not quite as bad shaft for it, but the engine has just been rebuilt (before I got the replacement shaft, which are like hens' teeth) and it's running quite nicely!

Eric, you are doing a great job.

[Uncle Bob]

Those splines are definitely a Suzuki weak spot. It's bloody annoying on my X7. I have a not quite as bad shaft for it, but the engine has just been rebuilt (before I got the replacement shaft, which are like hens' teeth) and it's running quite nicely!

Eric, you are doing a great job.

You missed this one on Ebay then - looked unworn https://www.ebay.co.uk/itm/176194720840 and the whole gearbox went for £66 inc postage - someone bagged an absolute bargain.

UB

[tigcraft]

I did miss it! Do they definitely fit or does it need machining?

[Uncle Bob]

I did miss it! Do they definitely fit or does it need machining?

Sorry that was for SmallKat and his X7 - we have previously talked about the wear on the X7 shaft when I found mine was knackered.