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Thread: Suzuki GT250B - Winter project 2017

  1. #91
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    Default Re: Suzuki GT250B - Winter project 2017


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    Chelmsford, alternate for Tuesday was a ride on the Tuono if it's nice and that could be towards Tunbridge Wells. For my 50th 5 years ago I did a days green laning round Essex on my DT175, did about 60 miles and ended up wet, muddy and cold, really enjoyed it.

    I'll bring the Rioja.

  2. #92
    At Work Pugwash's Avatar
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    Default Re: Suzuki GT250B - Winter project 2017

    This week I have been mainly finding out that just because a carb kit says it is for a 1977 Suzuki GT250, doesn't mean that it is. They've gone back to the seller for a refund.

    My tip for the week is that when you spend time repainting your switch gear, and then re-assemble it, having left it somewhere warm for three days to harden off, make sure you tape it all up before you put the actual switch gear back inside the cases, otherwise you will chip off the paint that you have painstakingly applied. Do not ask me how I know

  3. #93
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    Default Re: Suzuki GT250B - Winter project 2017

    Having seen it in real life , it looks good (even the wife thinks so) did you laquer over the switches once you'd done the red?

    Pity about the carb Kit, strange that not one bit matches. Still waiting for mine from Germany for the Guzzi.

    Inspired by my visit, I've now bought a dental pick set (get those tricky rubber bits out the carbs) and a wheel balance frame like yours. Not got an immediate use for it but I'm sure it will come in handy, as two tyre changes ago the tyre place didn't balance the front wheel properly and the vibration was dreadful in Germany at 120mph on the autobahn. So now I can do the Tuono, Le Mans and DT just for the fun of it.

  4. #94
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    Default Re: Suzuki GT250B - Winter project 2017

    Lacquered it all, but it was such a pig refitting the switchgear that the two halves rubbed together and took a patch off. If I'd put a bit of tape around the casing it would have been fine.

    I've just ordered a pair of long nose circlip pliers, as I've just spent an hour trying to refit the m/cylinder piston without success. Now going to go for a walk with the dogs and ponder on the pointlessness of existing in relation to restoring motorcycles.

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  6. #95
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    Default Re: Suzuki GT250B - Winter project 2017

    Been a bit quiet lately, so here's a quick Christmas update.

    I've rebuilt the forks with the new stanchions, replaced the steering head bearings, re-bushed the swing arm, and rebuilt the ironmongery on the front and back wheels. The Master cylinder and the front caliper have been done, and are awaiting fitting.

    A fairly pristine back mudguard came up on Fleabay recently, and using my tried and tested "bid last moment and ridiculously high" strategy in the hope that I'll get it for a reasonable price, I secured it. Unfortunately I wasn't the only one using this strategy, and I won it by a fiver, thus now owning the most expensive second hand chromed mudguard in the world Don't ask how much, as if Mrs Pugwash finds out I'm a dead man.

    Next up is an initial assembly to make sure I've got everything, and to replace the odd sized bolts that have found their way onto the bike in the last 40 years.

    After Christmas I'm going to start on the engine. I've had the top off already, but I'll dismantle the whole caboodle and get the cases vapour blasted, before getting the crank rebuilt, and the clutch sorted.

    Happy days!

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  8. #96
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    Default Re: Suzuki GT250B - Winter project 2017

    Quote Originally Posted by Pugwash View Post

    Next up is an initial assembly to make sure I've got everything, and to replace the odd sized bolts that have found their way onto the bike in the last 40 years.
    I replaced most of the bolts on my GS750 with stainless steel ones, so I have quite a large selection of period Suzuki bolts. Post a list of what you need and I'll see what I can match up for you

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  10. #97
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    Default Re: Suzuki GT250B - Winter project 2017

    Quote Originally Posted by Druid View Post
    I replaced most of the bolts on my GS750 with stainless steel ones, so I have quite a large selection of period Suzuki bolts. Post a list of what you need and I'll see what I can match up for you
    I'll be in touch......

  11. #98
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    Default Re: Suzuki GT250B - Winter project 2017

    Well it's been a while, but after a delay while I replaced the fork seals and powdercoated the lowers on the VFR, and even longer while the temperature was sub zero, I've at last got back into the garage, and I'm now working on the engine.

    The plan is to have the crank rebuilt, new clutch, and to have the engine cases vapour blasted. I'm going to get the bores checked, and if necessary I'lltake it out to +0.5 rebore. I don't really have accurate enough tools to check it myself, although it looks and feels ok. Maybe I'll see an internal micrometer at the car boots this year.

    The crank was gummed up and varnished by old 2 stroke and fuel that was sitting in the crank pit. I've cleaned it, and it all feels good, but the seals must be buggered after 40 years, so it needs to be sorted. if anyone has a recommendation for a good crank man, please let me know! I have a local guy who rebuilds car engines, but I don't know how keen he'll be on a 40 year old smoker.

    The lift I scored off Didge is making it a lot easier on my back . Thanks mate!

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  13. #99
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    Default Re: Suzuki GT250B - Winter project 2017

    Alpha Bearings for your crank. Horrible website but they will do a good job on your crank. They're in Netherton in the west Midlands so not exactly local to you though.

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  15. #100
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    Default Re: Suzuki GT250B - Winter project 2017

    Another midland place is Nametab Engineering in Redditch. Did an excellent job reboring my Arrow.

    http://www.nametabengineering.com/services/

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  17. #101
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    Default Re: Suzuki GT250B - Winter project 2017

    ...and breathe! Sorry for the long absence again, although this is more down to the sins of others. I have at last got the crank rebuilt and the barrells taken out by 0.5mm despite the best efforts of various nameless engineering firms to wait for hell to freeze over before doing what they promise. I've had the engine cases vapour blasted, and very nice they are too. All I have to do now is remember where I put all the little ziplock bags, and how all the bits inside them fit back together. i might even finish this winter project before the next winter starts.

    The photo with the crank pins show why it is a really good idea to rebuild a crank that's sat for twenty years in a garage in Eastbourne, near the sea. One side is just about marginal, but on the other side the chrome has worn off the pin, and the case hardening inside the con rod big end has broken down. The big end bearing is toast. The large bearing is somewhat crunchy too. The crank now has new bearings, rods, seals and crank pins throughout, so should be good for another few years.

    Next step - put it back together, sling it in the bike and see if it flies

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  19. #102
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    Default Re: Suzuki GT250B - Winter project 2017

    In my experience of building 2 strokes. Clean everything and every mating surface.
    Then clean again etc etc etc...

  20. #103
    Should Get Out More Julian_Boolean's Avatar
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    Default Re: Suzuki GT250B - Winter project 2017

    I bet the crank work wasn't cheap, looks very nice though.

    Sent from my SM-T560 using Tapatalk

  21. #104
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    Default Re: Suzuki GT250B - Winter project 2017

    Quote Originally Posted by Julian_Boolean View Post
    I bet the crank work wasn't cheap, looks very nice though.

    Sent from my SM-T560 using Tapatalk
    Altogether the crank and the rebore incuding parts and labour were just shy of 600. I'm going to make a small fortune on this restoration. Shame I started off with a large one etc etc.

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  23. #105
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    Default Re: Suzuki GT250B - Winter project 2017

    Schrodinger's Motorcycle.

    Today, for the first time since 1996, the genie of internal combustion manifested itself inside UDY187S. It only bloody works!!

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