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 ....

Taking first look.jpg

[ukjules]

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

Swinging arm needs welding - wish i could weld.jpg

[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 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 ....


IMAG0517.jpg

[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 ....





IMG_0276.jpg