Hi Tony. Its a Suzuki TS185 clutch bought from good old fleabay. The Suzuki one comes riveted to its primary drive gear with an integral cush drive. We have had to dispense with that and reduce the size of the cush drive lugs on the back of the basket. Some machining (thinning!) has had to be done o...

Very similar to what we have done Brian. Main difference is that ours will carry a tubular steel subframe to carry the seat and mudguard. Nice work. Like the alloy cups to locate the seat rubbers.

With regards to the rear shocks, I have made an inner subframe for the frame with lugs so that we can fit conventional dampers. Haven't got round to the front ones yet, but they are going to need some attention as the alloy sleeves that fit into the top of the main body are badly worn.We have skimme...

Its in the back of our minds John.

Newly machined (spark eroded) Suzuki TS185 clutch centre to fit Arrow mainshaft

Hi David. The skills will come flooding back, I'm sure. And once you start, who knows where it will end. I have the ideas but limited skills. A Chester (chinese) lathe for me is about as far as it goes. Mind you I did surprise myself a few years ago when I made some fork parts for our Scott ! My nep...

Ellis' option 2 1st gear uses 18-28. This may well be what we will end with. 2nd and 3rd are the same as ours, probably using 2 x 3rd gear sliding dogs.

We have some pinions from the 'normal ' Burman GB boxes that we have machined, and the spline sizes (or at least some of them ) are the same as the 2 strokes as are the tooth forms. The 4 stroke GB sleeve gear for instance can be made to fit but it is considerably wider across the teeth. The other G...

I know that Roger (Jess) has had Ellis do a gearbox for him. Not sure if he's used it yet. No doubt he will give you his thoughts. We have made our own using existing Burman components somewhat altered. The pinions we have used going from 1st are 20/26, 22/24, 24/22 , and a final reduction of laysha...