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CharlieT 02-16-2013 08:02 PM

Might as well get another thread or two going here besides the Servi-car build. In addition to the servi-car another bike we are building is a 1972 Suzuki GT250.

A direct decendent of the famous Suzuki X6 Hustler. Ours is a bit of an oddity in as it is a 1972 model. According to Suzuki the GT250 was not exported out of Japan to Europe and the US until 1973. That the one we have is indeed a '72 was confirmed by the substanial difference in wheelbase between the '72 JDM model and the '73 & later export model.

The bike we started with was actually a hodgepodge more or less. Had a later '70's front end, a late 60's t250 tank that had about an 1/8th in brushed on paint job.

SO the first step got underway....the fun and fast part, the tear down.

CharlieT 02-16-2013 08:18 PM

Intent on this project is to build build a little 250 2/ cafe racer. One of the first things we did was to go thru a pile of parts we had in the backroom. Came across a set of wheels and forks from an '87 Yamaha SRX250. That should give it a bit more modern look to it, plus a late '80s set of brakes versus the early '70s.

CharlieT 02-16-2013 08:23 PM

Moving onto the engine.

Condition was remarkable. Both cylinders and pistons were right on with original factory new specs!! Rest of the engine was jst as good, SO a light brush hone and a set of new rings was all it needed besides a carb cleaning.

After that, it was off to the degreaser, sandblaster the paint booth and buffing wheels.....

CharlieT 02-17-2013 07:26 AM

The seat and the pipes have both arrived, but still waiting on the tank. Seat position is approximate until we get the tank in.

Playing around with the pipe position. Trying to decide to tuck them in tighter up under the frame, which would need both the center and side stand to be cut off, then a new side stand fabricated. Or leave them just outside the frame in which case the side stand would go, but the center stand could stay. Even with the pipes outside the frame, clearance before they would scrape is pretty substanial, enough that you wouldn't have any chicken stripes showing.

flemsmith 02-18-2013 08:27 PM

Did you really sandblast the engine?


CharlieT 02-18-2013 08:53 PM

Parts of it, yes. Removed the side covers and blasted them. Also the cylinders and heads after they had been removed from the cases. After blasting, we typically dunk them in the ultrasonic cleaner as that does the best at removing any residual grit. Then those areas we are going to polish are are taken to the buffing wheel, such as the circular area around the Suzuki logo on the right side cover.

CharlieT 02-28-2013 08:47 AM

Progress finally being made no the GT250. Finally got the tank in and also decided to tuck the pipes up under the frame for more cornering clearance.

WIll have to fabricate or relocate the sidestand as we cut off the center stand and its brackets.

davesupreme 03-01-2013 03:30 AM

yeah, man.... keep goin', more pics.... this looks good!... :evil

yokesman 03-01-2013 08:45 AM

I assume you replaced the crankcase seals also.

CharlieT 04-07-2013 03:58 PM

Ok, its been a while for this one, but its about at the point to get taken apart for finishing & prep before powder coating and painting.

Got the headlight mount brackets made.

Also got the taillight mounting taken are of, along with the battery. Decorative tank strap also done.

AtLarge 04-11-2013 04:37 PM

Shaping up nicely. Always had a thing for the ole ram air motors. :raabia

Old Mule 04-11-2013 05:22 PM

the Suzy
I liked my GT250 a lot, much more refined and "grown-up" bike than the Yammer RDs. Foolishly gave it to my daughter.
If I were going to build one up now I would just google "Eddie Crooks suzuki", saw it in the IOM and it's a beauty and a classic.

CharlieT 04-11-2013 07:58 PM


Originally Posted by Old Mule (Post 21165249)
I liked my GT250 a lot, much more refined and "grown-up" bike than the Yammer RDs. Foolishly gave it to my daughter.
If I were going to build one up now I would just google "Eddie Crooks suzuki", saw it in the IOM and it's a beauty and a classic.

Googled that and came up with all kinds of pics. Kind of like this full-fairing version.

Gramp-Z 04-28-2013 07:56 AM

I had an X-6 Hustler , 68' . I dumped a ton of money on mine to make it look like a 74' . Even ordered a 74' gas tank ($265 or so) in 1974 . Fabbed my own Ram Air etc . For a bike made in 68 it was pretty impressive at the time . Got mine running pretty good . By modern standards it was a pig , but back then it was a very quick little bike . Without any effort at all you could outrun the handling , brakes and tires . The headlight was great for low RPM in first gear and save the other 5 gears for daytime . I noticed the Water Buffalo in the background . I fought off the urge to buy one of those . In the early 80's I came very close to buying a wankle bike . I will be following along on this build , it should be a fun project .

Blakebird 05-03-2013 02:17 PM

I had a black '67 X6 Hustler scrambler in high school ('70-'71)....first engine I ever siezed and rebuilt. Loved the thing except for it's habit of popping out of 2nd gear shifting up.

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