1980 gsx250 project

[ukjules]

Just thought id start a project post.
Bought a total wreck of a GSX 250 but one that has potential.

Love these bikes as was my first road bike. Good times at 17 !

 

[ukjules]

Got it started so the engine is ok.
Mixture was 3 1/2 turns out and plugs barely a gap.

Set to 2 turns out on mixture and .7 on plugs and it goes ....

 

[ukjules]

Swinging arm small rust hole. Wish i could weld be so easy to fix.

 

[ukjules]

New master cylinder and front brakes reconditioned today.
After a boost and a trickle charge the battery is fine
Rear brakes now work ok.
Back half cleaned up, terrible rust on frame but only surface.

Forks - i will try and clean them up but they might be too rusted and thus keep blowing fork seals.
Gonna try the metal polish / aluminium foil scenario.
Rear shocks - wrecked and need new ones.
Also need a new seat - the one is shot totally top and metal seat casing.

 

[ukjules]

Big day - both forks out and split apart. Possibly the easiest forks I have ever done.
Usually it verges on nervous breakdowns doing them but zero issues.

Glued some more panels

Started cleaning up the forks and 20 mins on them has made them like new.
will post picture of before and after.
But the bike was a wreck, total wreck. Will polish and clear coat both of them.

Front wheel removed and again it was awful.
It is now ready for some paint. think satin black is original ' ish.

Still need a seat !

 

[ukjules]

-both fork seals installed - the easiest bike to do that on !
-Forks polished and clear coated
-Fork stantions saved with polishing etc - they were pitted but they will be ok
-various parts removed for spraying - satin black

Issues:
- Seat wrecked i think and need another
- Shocks needed
-Swinging arm needs some weld
-air box internals still needed
-exhaust - so need a cool exhaust for this but where ?

I have decided to leave the frame , tank and painting the wheels for my
next years winter project (i wasnt gonna start this bike until then)

i reckon in 2 weeks this should be going and on the road !

 

[ukjules]

Current state - getting there

Current state - getting there

Current state of the bike with the work on the front end complete.
(I will do the steering head next winter)

i will sort the rear wheel out tomorrow and post.
I might even sort / polish the engine side casings.
i hate doing wheels.

will update post

 

[Buffalo Bill]

Looks like a good project, just wondering why own a 250cc?
Not being a wise as.

 

[ukjules]

This was my first ever road bike when i was 17.
The same colour and everything . I went everywhere on it.

I am not really a speed person anymore (I have done that with fireblades and the likes)
and much prefer to cruise about.
Cruising about on this will be great. It can do the bad weather chores.
I also have my first ever motor vehicle i ever drove / bought in the garage .... a 1977 rd 250.

AND it is so much easier than a monster large bike to do as a nut and bolt mechanical project.
I am doing a GPZ 750 r1. I bought that as a wreck and it is so much harder to do.
I simply think Suzuki engineering and design even back in the 80's was better.
Its better thought out for mechanics ?

8 hour day tomorrow on it and the back wheel will be done and the casings polished up !

 

[ukjules]

Both wheels done - simply cleaned and ally polished / rubbed down.
Started on the engine cases but will polish up fully next winter.

Need to get this going for inspiration so valve clearances tomorrow and then a start up
and tune.
Also some spraying of parts ....

 

[JamesWhut?]

Looks like a good project, just wondering why own a 250cc?
Not being a wise as.

"Its more fun to go fast on a slow bike than slow on a fast bike."

 

[Wallowgreen]

250cc was the biggest bike you were allowed when I passed my test at 17 so there was no option to ride a bigger capacity machine. I bought a brand new GS250TT and likewise, I went everywhere on that. Eventually sold it to buy my first car... groan

Found another one over here a while back in a dreadful state. Was a farmers field bike (yes it was covered in cow crap) and it's down to the frame for a restoration right now. Good luck with yours Jules, looks to be coming along nicely - be a cool trip down memory lane when it's roadworthy.

 

[ukjules]

Good luck on the gs 250 tt !
I am hoping to get mine going / driving it this week. I am rushing a bit
but this was always my next winters project. As I am not doing the frame till then
it is slightly easier.

I am considering buying a mig welder 140 one with gas.
or is it better left to professionals ? If i could weld up exhausts it would be worth it.

 

[Buffalo Bill]

I was thinking the same thing about welding, especially what I got some prices for welding.
The gas was like $180 including the tank, plus learning how to do it.
Professional welding was per hour and my job would have taken less than an hour, so it would have been less than $50 and perfect.
I did my own without gas, because I wanted to learn. However exhaust pipes need to be sealed tight, so I would hire a pro for those.
I suggest you find a body and paint shop that likes to work on custom cars and racers, because they'll have the best attitude about your project. You won't have to look far.

 

[ukjules]

I wanted to post more pictures but only allows one ?

Anyway today was spraying.
The small parts off the bike rubbed down and some sprayed
with primer and some direct with epoxy.
Sort of doing a test on which is best but that epoxy paint is mega and does not need primer.
(I did another bike of mine with epoxy and they look fantastic. (epoxy / clear)

Also did the valve clearance taking the cam cover off. (Only one stripped thread)
Valve clearances slightly out by o.o2 on some.

Sorted one thread on the cylinder head exhaust.

I expect the bike to be going by the weekend.

Still need a seat ! , exhaust and air box internals ....

 

[ukjules]

As for mig welding (with or without gas)
@ B bill - is it possible then (say on mower decks - for the non trained ?

Exhausts i agree are probably too much but mine is rusted so i might try on the back
box as i have nothing to lose.

 

[Wallowgreen]

You can post more than one picture but not by importing the picture directly you have to use a hosting site like photobucket or imageshack then link to them. Info on how to do that if you're interested can be found at:

http://members.dslextreme.com/users/bikecliff/

on the left side of the page first link under the flashing icons around the "READ ME" link

 

[ukjules]

Think for future projects i need to teach myself mig wleding
and also perhaps one of those zinc plating kits ?

All removable parts now sprayed , primed, base and clear coated.
Used that epoxy paint which i think is brilliant.
looks excellent but the frame which i am not doing will show !

pics to follow and a possible start up movie before the weekend is out !

Electrics are going to stump me.
Ignition circuit ok but there are bodged bare wires around the battery which
is to do with the lights i am sure. might need some help ...

 

[ukjules]

Update.
This bike has almost cracked me several times.
I cant seem to understand why but the bodged terribly electrics may have something to
do with it - as i am useless at electrics but have to learn.

A good chap has sold me an exhaust and swinging arm . (When i learn how to weld i will
sort my other one out myself)
I actually went up for an airbox but came back with other things i needed more urgently.

Anyway started putting it back together as i simply must ride this thing before i go any further.
Remeber it was a wreck carried to my house on a trailer.

Jobs done:
Carbs stripped as it was running like a dog.
Incredibly not too many stripped bolts and a total dismantle and put back together
has made the bike sing ! So timing, valve clearances, Plugs, mixture, carb dismantle
me sorting out new earth wires has got the bike going well.

now it is electrics.

 

[ukjules]

Calm yourselves calm yourselves ! I promised video and that it would go by the weekend !

[video]http://vid1360.photobucket.com/albums/r659/rainstick2/first%20start%20up%20tuned_zpsow3p8ng8.mp4[/video]

Tomorrow will continue:

-Sprayed parts back on
-try and put a new seat cover on (have rubbed down and rust treated the seat pan)
-Balance the carbs (forgot that ) All other possible tuning done
-Test run

Still need (or want)
- A original seat
- A 2 into 2 exhaust

both of these are hard to find but it goes now and i can wait.
Also this bike was meant to be next winters project so i am a bit ahead but the frame does
need to be powder coated and loads more spraying.
I always have to get the bike tuned and mechanically ok before i do that though.