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Old 02-16-2013, 08:02 PM   #1
CharlieT OP
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Hustler

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.


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Old 02-16-2013, 08:18 PM   #2
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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.



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Old 02-16-2013, 08:23 PM   #3
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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.....
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A good bike mechanic only needs two tools, WD40 and duct tape. If it doesn't move, but should, use the WD40. If it does move but shouldn't use the duct tape.

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Old 02-17-2013, 07:26 AM   #4
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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.
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A good bike mechanic only needs two tools, WD40 and duct tape. If it doesn't move, but should, use the WD40. If it does move but shouldn't use the duct tape.

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Old 02-18-2013, 08:27 PM   #5
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Sandblast?

Did you really sandblast the engine?

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Old 02-18-2013, 08:53 PM   #6
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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.
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A good bike mechanic only needs two tools, WD40 and duct tape. If it doesn't move, but should, use the WD40. If it does move but shouldn't use the duct tape.

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Old 02-28-2013, 08:47 AM   #7
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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.
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A good bike mechanic only needs two tools, WD40 and duct tape. If it doesn't move, but should, use the WD40. If it does move but shouldn't use the duct tape.

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Old 03-01-2013, 03:30 AM   #8
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yeah, man.... keep goin', more pics.... this looks good!...
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Old 03-01-2013, 08:45 AM   #9
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I assume you replaced the crankcase seals also.
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Old 04-07-2013, 03:58 PM   #10
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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.


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A good bike mechanic only needs two tools, WD40 and duct tape. If it doesn't move, but should, use the WD40. If it does move but shouldn't use the duct tape.

http://www.facebook.com/pages/Checke...22319847810910
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