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Project 300 "this is not sparta"

  • Thread starter Thread starter razor02097
  • Start date Start date
razor02097 said:
Well I took the front and back wheels off. Looks like the original brakes are still on... I first tried scotch brite because the front shoes had corrosion on them... After I noticed there were deep gouges from where the corrosion was...
I chickened out and ordered new front shoes. Also found the chain has a few spots the links are seized... I just decided to order new sprockets and bikemaster o ring chain. I'm in the process of restoring the hardware for the front and rear wheels.
Click to expand...

Well done! New shoes are best, especially when talking the front brake!

If the lining has a layer of surface rust like my rear drum did, just get some coarse sand paper and give it a rub over to brake up any glaze that might be there.

Also good call on doing the chain and sprockets. I've seen a few guys on here take the shortcut and just do the chain or one sprocket...
 
pete said:
Well done! New shoes are best, especially when talking the front brake!

If the lining has a layer of surface rust like my rear drum did, just get some coarse sand paper and give it a rub over to brake up any glaze that might be there.

Also good call on doing the chain and sprockets. I've seen a few guys on here take the shortcut and just do the chain or one sprocket...
Click to expand...

My thoughts exactly... If I'm going to spend hard earned money, safety systems are the first thing.

Last night I put on the new tires. I went ahead and bought new tubes also since the old tubes are probably original... I got lucky and my own weight was enough to break the beads.

IMG_20120125_164850.jpg


Here are the old tires... and here is a big reason they really needed to be replaced...
IMG_20120126_090602.jpg


New tire


IMG_20120125_175957.jpg


Now I know I needed some sort of lube to put the tire on. WD-40 won't work... so I rummaged under the bathroom sink.
IMG_20120125_180700.jpg

Only thing was it turned the tires a strange brownish brick color....


I'm only kidding.... it's just soapy water in that bottle :lol:

One side in time for the tube
IMG_20120125_181040.jpg


Setting in the valve stem
IMG_20120125_181234.jpg


Spooned the other side on
IMG_20120125_181527.jpg


Repeated for the back.... job done
IMG_20120125_233616.jpg


Last thing was to pull the hardware out of the evaporust bath
IMG_20120125_233547.jpg
 
Mate that is some nice work!

You're gonna have to put her up for BOM when she's done with attention to detail like that :D

Would be nice to see a 300 on the front page!
 
That would be cool :) I'll do my best

Parts arrival!!!!

Suzuki delishiousness! With a little k&n cherry ;)
IMG_20120126_214338.jpg



Too bad I'm still waiting on other parts or I would start putting things back together :(
 
Last edited:
ScrumDown said:
Check this DIY out ....

http://www.youtube.com/watch?v=P6sH8WRl6yI

My edit ... OOPS! Looks like I should have read farther in the thread before posting about the time
Click to expand...

That's pretty neat! I would have never thought to do that :eek: I got lucky and the beads broke with just my weight. I used tire spoons to get the old off and install the new.


A little update...

I compared the old rear shoes to the new... man father time wasn't kind to those old shoes!

IMG_20120127_193408.jpg


Glad I'm getting new for the front too :eek:

Took the forks off and changed the seals and changed the fork oil
IMG_20120127_233611.jpg
 
Well yesterday I put her all back together and went for the first ride. It was about 40*f out so not the warmest ride.... I'm wondering what a 300 runs at engine speed wise at 70mph? I don't have a tach and I don't want to burn up the motor.
 
Awesome! Bet that was satisfying right? :D

Woodsy on here mentioned his GSX250 spinning quite high at 100km's an hour but can't remember how high now... maybe 6000/7000 RPM?
 
It was definitely nice to ride

I was able to maintain about 70mph but I didn't want to push her any harder than that.
 
Received chain, front and rear sprockets and the front brakes. I have been riding around as much as I can. Today it was 60*F! I'll take it! Definitely have to do something about the clutch... it seems to slip if I change up hard. I still have to do an oil change.

One thing that I'm pleased as punch is she is not cold blooded one bit... I remember my old Honda 650 was a pain in the rear to try to warm up. I would have to play with the choke for a good minute or so before she would even idle. The GS fires up at half choke and 5 seconds later I push in the choke. Easy as pie.
 
Well got the front brake shoes on.

Here are the old shoes and the new ones.
IMG_20120202_163959.jpg


Here are the new shoes installed. I was finally able to adjust the brake cam timing properly!
IMG_20120202_164302.jpg


New sprockets and O ring chain. Total = under $100
IMG_20120202_164007.jpg


Installed!
IMG_20120202_184958.jpg


Nice thing is I didn't realize that the stock size chain is in fact 108 links... that chain happened to be on sale... I was going to get a 106 but the 108 was cheaper... I'm glad I did!

IMG_20120202_184205.jpg


Also installed the missing fork reflector
IMG_20120202_184945.jpg


I still have to get the oil changed. I guess I could just start the engine and kind of warm it up... but I think I'm going to wait until I can give it a good ride before changing it.
 
Nice... glad to see you taking care of all those maintenance tasks :)

And I still can't believe how clean that thing is! She looks great!
 
razor02097 said:
Well yesterday I put her all back together and went for the first ride. It was about 40*f out so not the warmest ride.... I'm wondering what a 300 runs at engine speed wise at 70mph? I don't have a tach and I don't want to burn up the motor.
Click to expand...

In 5th gear it will run that all day -- ride on.
 
good to know. I am able to easily keep up with traffic which was my concern. I figure I'm around 7.5k RPM at 70MPH.


UPDATE:

Since day one I've been having some issues with the speedometer randomly cutting out and kind of "twitching" during steady cruising speed... I was wondering if something was gumming up the speedometer. I disassembled the speedo and lubed everything... It didn't seem like anything was wrong. I cleaned it up, touched up the needle tip and reassembled.

IMG_20120203_205531.jpg


Well I thought if it isn't the cable, isn't the speedo.... it has to be the drive... well taking the front wheel off I didn't really see anything different... I may not be an expert but I'm pretty sure this drive washer shouldn't be bent like this...

0203121942a.jpg


It's funny... Sometimes it is the simplest things. I never knew any better since it was already bent... I'm just glad I went on a hunch and straightened it up. Speedometer works great now! Still reads too slow but works great!



Also found that my high beam and neutral lamps were burnt out. So now my dash is working 100%... how rare is that? Also finally got to the oil change and adjusted the clutch linkage while I was at it. Man what a difference! I can select neutral at a stop now!



I need to check the valve lash... That is something I haven't gotten to yet.
 
Great job on the speedo!
As for the drive washer, the part that wears out is the inside tabs.
Perhaps it is still "skipping" and that is why it reads a little slow and/or the tire diameter is taller.

Daniel
 
Yup taller front tire... Wish there was a way to calibrate the speedometer...
 
UPDATE:
After suffering the deafening pop pop sound when ascending hills I decided to go for broke with my stock mufflers... I thought about several things including fabricating a removable baffle. I ended up stuffing the hollow cavity with #2 steel wool then fitting a piece of old fork spring in the middle.

I have a set of late model Suzuki mufflers from a busa I fitted to my Honda... I am entertaining the idea of installing them. The only thing is they weigh almost literally a TON! I don't really want to add so much weight to the poor 300. The other thing is the center stand clearance. I know I will have the same issue with the 300.


Here is a pic of what I'm talking about...

SN850001-1.jpg


They are still on the Honda. I would be willing to cut up the exhaust but I'm not 100% sure I want to do it yet. I would be open to suggestions. I would like a quiet exhaust as a personal preference.

Time to do something about the stupid start button... it takes a little fiddling sometimes to get it to work...

0204121356a.jpg


0204121348b.jpg


I use deox it, another "wonder" chemical. Like Flitz deox it does a great job. It is designed to destroy corrosion and keep connections from corroding again. It is very popular in the music scene which is where I heard about it. I also used it to get the corrosion off of the engine fins but by the time I was done it was too dark to take a picture...
 
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