Ive got a question I thought someone might be able to answer. Ive got a suzuki dt25c that has a cracked intake manifold (circled below). Ive also got another good intake manifold from another powerhead of the same year and model. Would it work to mix and match these parts when rebuilding this engine to replace the cracked intake?
Good engineering practice would say NO, as the part involved is one half of the crankcases that bolt around the main bearings.
A matched pair would probably be line-bored at the factory.
In reality it would probably be OK.
Being a 2-stroke a good seal is required in the crankcase, and you would need to nip the bolts up very gradually to the specified torque whilst checking all the time that the crank is running free.
