I'll try and put some pics up tomorrow. We did think about opening up the crank hole to fit the torque converter, but then we'd still have the issue of the different offsets of the way the flex plate fits the torque converter. Too many mods to make, maybe. I've put out some posts on a couple of boards, maybe someone knows a way, might be as simple as getting the correct tc and flex plate, might be a hole cans of worms I've opened up.  I'm just gonna sleep on it and go for a ride on my Harley tomorrow, the weather is supposed to be real nice. 

Is there part of a pilot bearing in there?

The hole in the crank of my 98" kick is 30mm

We all looked it over real good and there didn't seem to be any type of pilot bearing in the end of the crank. Is yours an auto or manual? Second question, why would the ends of the crankshafts be different anyway? They're both 16 V 1.6's.  And 30mm? I really have to go out and remeasure it again. Now I'm really confused.  I got 20mm ( aprox ) for my 96, that's a BIG difference.

deep breaths!

Hope there is a easy answer to this.

Any of those Trackicks your workin on John happen to be a 4 speed auto?

We all looked it over real good and there didn't seem to be any type of pilot bearing in the end of the crank. Is yours an auto or manual? Second question, why would the ends of the crankshafts be different anyway? They're both 16 V 1.6's.  And 30mm? I really have to go out and remeasure it again. Now I'm really confused.   I got 20mm ( aprox ) for my 96, that's a BIG difference.

I have a 5spd, but also have a 96 auto engine at the shop and it also has a 30mm pilot hole. I can not see Suzuki making two different crankshafts for 5spd or auto trans applications. Every cross reference shows them being interchangable. I could see them adding a sleeve to change the pilot opening, but not two different machining processes.

The pilot bearing specs are thus,  
Clutch Pilot Bearing I.D. : 10 mm
Clutch Pilot Bearing O.D. : 30 mm
Clutch Pilot Bearing Width : 9 mm

Also, IIRC there was a spacer between the flexplate and crankshaft on the 96', it looked like a large washer with the bolthole pattern.

Also, IIRC there was a spacer between the flexplate and crankshaft on the 96', it looked like a large washer with the bolthole pattern.

That washer is present on other years as well, I think it adds rigidity to the center of the flex plate.

That washer/spacer is far too thin and small in dia to provide any rigidity, it is merely a spacer.

Look very close at the end of the crankshaft.  I have not seen a difference in the end of the cranks between a 5 speed, 3 speed, or 4 speed in a 1.6 trackick.  There is a bushing, that fits in the end of the crank on 3 speed trackicks (and probably 4 speeds, I don't remember for sure though).  If the crank has anything sticking out of the center of it, then it is a bushing and you need to pull it out (it may be stuck in there good).  The end of the crank should be an "innie".

Color me embarrassed    went out this morning after a good nights sleep and took a GOOD look at everything again, including my old engine and after giving it a close look I decided to take a pair of smooth jawed channel locks and see if the end of the crank would twist, and off it came , right into my hand, the elusive " spacer " with all the correct dimensions. Funny how three experienced mechanics couldn't figure that out.   Once that dilemma was solved all I had to do then was figure out why the torque converter wouldn't fully seat. After crawling into the engine compartment with a flashlight I finally figured that out too.  2 large slots in the tc fit into two large tangs in the trans.  The TC will go on and feel seated, but if you don't line up all 3 sets of teeth, small splined shaft, then larger splined shaft then the two big teeth, it's not in all the way. Took a few tries but finally got that too, and that solved all the fitment issues.  Now engine is in, mated to trans, bolted down and all wiring is connected. Heater hoses done, and next is to begin installing the accessories, starter, alt, ps pump, ac compressor and such and lastly the turbo system.   Gettin there ! Thanks everyone for your input on this and sorry for wasting your time. Lets hope it runs as good as it looks.

Right on Mike,  good to hear that you're getting it sorted out. Sometimes tired eyes can be more trouble than the thing we are trying to fix. Been having the same kinda luck working on my tow rig lately. Maybe we are just getting old

 went out this morning after a good nights sleep and took a GOOD look at everything again,

Well there you go.

Bob's your Uncle.

Glad we were able to steer ya in the general correct direction.

Thanks Guys, gettin it together a bit at a time.