Scooterotica

Hi all, I have an SR 190 kit which has been sitting in the box for years and I decided to put it on this week as my bike is off the road due to a gudgeon pin snapping. The kit is a Suzuki 64mm piston with the Indian SR cylinder. The cylinder was tuned by Guy Topper and it has a GP crank with a RD Conrod built by Charlie Edmonds so all together it cost me quite a bit of cash and I was really hoping for it to work straight out of the box. Anyway I have built it up and it is leaking basically it doesn't hold pressure at all. I have checked with soapy water and the air seems to be escaping from a small hole in the aluminium near the exhaust port. [youtube]https://youtu.be/V_rm7afkzXA/youtube]Is it possible to repair this or is the cylinder destined for the bin.

I viewed the video & think the barrel has a pin hole in the alloy casting, most likely porosity.

I would dismantle the engine & evaluate where the hole starts. Most likely in the exhaust port.

With luck, it will be a straightish hole that can be enlarged with a twist drill to the smallest drill size (if that makes sense ) to be pinned with some round bar having an interference fit.

It's the same procedure as repositioning piston ring pegs using the needles from a needle roller bearing. Or you could drill & tap to something like an M3 & Loctite a screw in, I suppose. Each end of the 'plug' will need dressing, obviously.

Whatever you do, if methodical & scrupulously clean, the repair should be a long term fix.

Personally, I wouldn't attempt the repair with something like JB Weld, preferring something mechanical, rather than chemical.

With the cylinder's provenance & likely potential, I wouldn't bin it just yet