Meanwhile back in the shop...

Discussion in 'Some Assembly Required' started by Fast Idle, Sep 14, 2019.

  1. Fast Idle

    Fast Idle Since the Sixties Supporter

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    Had a fantastic summer up here in Alaska with some of the best weather ever. It was epic.
    Now fall is here and so is the rain. It's a good time to start getting caught up on things before the snow flies in about six weeks.
    I did get some shop time in over the last few months and thought I'd post up from where we left off in the RD400 thread:
    https://advrider.com/f/threads/1976-yamaha-rd400-custom.1365454/page-55

    The RD build was complete and the jetting was dialed in. It runs excellent and stops on a dime. Got to ride it a lot this summer.
    Then another free bike showed up, a basket case 1993 RM125. Here's a quick recap.
    asfoundRM.jpg
    The frame had been powder coated so the chassis could start going back together once all the pieces were cleaned up and gone through.
    The engine on the other hand was pretty much destroyed.
    engine1.jpg
    The crank needed a rebuild, the cylinder was trashed, and so was the crankcase. Donor parts were found and ordered.
    The chassis was assembled while waiting for engine parts to arrive. The forks and linkage were gone through and it started going back together.
    P1120056.JPG
    Some cool new graphics were added along with a new seat cover to get this old bike looking good again. The FMF pipe was in good shape and got cherma-chromed.
    P1120209.JPG
    So that's pretty much where we left off other than the new arrival you can see in the picture.
    A 1970 Suzuki T-250 II Hustler.

    The RM engine build is up next.
    #1
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  2. DiggerD

    DiggerD DougFir from SuperDuke Days

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    Glad you had a great summer.
    I remember the Suzuki X-6 Hustler.
    This T-250 II...not so much.
    Will be more than glad to tag along.
    Cheers !
    #2
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  3. 3legs

    3legs Real men ride sidecars Supporter

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    The first bike I ever bought was a Suzuki T20 way back in the mid 70's. Learnt a lot about 2 strokes and engine seizures (mainly through doing the wrong things:lol3:lol3:lol3).

    Didn't put me off though. I still love my 2 strokes.:D
    #3
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  4. anonny

    anonny What could go wrong?

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    Looks great, I like the graphics.
    #4
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  5. radmann10

    radmann10 Derf Supporter

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    The Suzuki GT200 X5 was my first motorcycle, bought it from my older brother when I was 15. I still like a good 2-smoker for light weight, great power, and simple top end rebuilds!
    #5
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  6. Fast Idle

    Fast Idle Since the Sixties Supporter

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    I remember when one of the kids in school got a Suzuki T305. Man was that thing fast. Most of us were riding bikes like a Honda 90, 160, 305 or a 2-stroke single. That Suzuki kicked ass!
    I love all the old bikes from the late 60's to mid 70's and the 2-stroke street bikes were a major adrenaline rush.
    t305.jpg
    #6
  7. Fast Idle

    Fast Idle Since the Sixties Supporter

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    So after finally getting all the parts and pieces gathered up the RM engine was ready to get assembled.
    The donor case cleaned up nice.
    P1120098.JPG
    While the top end had detonated into scrap metal the transmission was still in good shape. With new bearings and seals in place, the crank was ready to go in and the case halves mated back up.
    P1120200.JPG

    I had put the crank in the freezer earlier and that made it a drop in so the case halves went together without any drama.
    P1120202.JPG

    Lower end complete, time for the new top.
    P1120225.JPG
    #7
  8. Fast Idle

    Fast Idle Since the Sixties Supporter

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    The original cylinder had been chewed on by the broken con rod but I was lucky enough to find a decent one for a reasonable price. It would still need to go in for re-chroming.
    It took a while for all that to happen. Ordered OEM SUZUKI piston, ring, pin, clips and bearing but the piston was on back order so that took 3 weeks to get. Then the cylinder and new piston got sent off so the cylinder could get plated back to standard bore. That was another two weeks.
    The freckles are a result of the process.
    P1120227.JPG

    Need to get the exhaust valves cleaned up and re-installed along with the cylinder studs.
    P1120228.JPG
    P1120230.JPG
    Good to go. They work nice and smooth.
    P1120231.JPG
    #8
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  9. r60man

    r60man Long timer

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    :clapYay, Fast Idle is back in the shop. It has been a long summer. :clap
    #9
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  10. more koolaid

    more koolaid Been here awhile

    Joined:
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    Bel Air Md.
    ^^^what he said :beerwelcome back
    #10
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  11. Fast Idle

    Fast Idle Since the Sixties Supporter

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    Installed the top end and set the engine in the frame.
    P1120234.JPG

    The pipe coating turned out nice. I was amazed that there was only one slight ding in the pipe.
    P1120233.JPG

    Repacked the silencer.
    P1120235.JPG
    Getting close now but need to fab up a clutch cable bracket. The original was broken off and there was no sense in buying a donor case because 95% of the ones I saw were broken as well. I did see one cover with the mount intact but how long would that last. Better off to just make one that won't break.
    P1120236.JPG
    #11
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  12. Fast Idle

    Fast Idle Since the Sixties Supporter

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    After seeing so many covers with the broken off mount it made me wonder if there were any aftermarket fixes for it. Surely there would have to be. It was too common a problem.
    Searched high and low but turned up nothing.

    So I made a template and found a piece of .063 4130 to make the bracket.
    P1120237.JPG
    Hacked it out and then dressed it up with the belt sander and files.
    P1120238.JPG
    Got lucky and it fit the first time without having to slot either hole.
    P1120239.JPG
    Made the second part and welded them together.
    P1120241.JPG
    #12
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  13. Fast Idle

    Fast Idle Since the Sixties Supporter

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    This one's not going to break off.
    P1120242.JPG
    P1120244.JPG
    A little paint and it's done.
    P1120249.JPG
    P1120250.JPG
    #13
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  14. Fast Idle

    Fast Idle Since the Sixties Supporter

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    Installed the radiators and filled the system. Ready to fire it up.
    P1120266.JPG
    Fired in just a few kicks.
    Then the petcock decided to start leaking so I had to shut it off and fix that.
    Rode it around a bit and put a few heat cycles on it. It rides nice so I'll go ahead and put some new rubber on it. Also take some dings out of the rims while I'm at it.
    The current tires aren't going to cut it.
    P1120267.JPG
    #14
  15. r60man

    r60man Long timer

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    #15
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  16. Fast Idle

    Fast Idle Since the Sixties Supporter

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    Some one should. Looks like they ran that cover from 92-2000 before changing the design. Having that break off during a ride might not be a show stopper but it sure would be nice to have a fix in your tool kit that installs in a few minutes. Or just cut the stock one off and put on one you don't have to worry about. I can just imagine the second line of expletives after the initial WTF? Like are you f'in kidding me? I've got to replace the whole f'in cover.:photog
    #16
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  17. Fast Idle

    Fast Idle Since the Sixties Supporter

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    Tires & tubes showed up.
    P1120299.JPG
    New wheel bearings too.
    tires (1).JPG
    Got the rear spooned on yesterday.
    tires (2).JPG

    These Kenda Millville II tires had great reviews so that's what I went with. Price was right too.
    tires (4).JPG
    The rear can be put on one way for soft or the other way for intermediate. I went for intermediate.
    tires (5).JPG
    #17
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  18. Fast Idle

    Fast Idle Since the Sixties Supporter

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    Pulled the front wheel and got the tire removed then pulled the bearings.
    Had to make a wedge puller to get the first bearing out. There was nothing to get a drift on from either side.
    tires (6).JPG
    tires (7).JPG

    Now the other bearing can get knocked right out.
    tires (8).JPG
    This ding needs to get heated up and straightened. I'll give it a spin on the truing stand after that for a quick check before the tire goes on.
    tires (9).JPG

    Should finish up today and the bike will be done.
    #18
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  19. Fast Idle

    Fast Idle Since the Sixties Supporter

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    Finished up the front wheel and got it back on the bike yesterday.
    The build was complete and the RM was ready to ride. Break-in was done per the Suzuki manual so I took her out for a little roost'in. What a fun little bike. The new tires are great!
    P1120313.JPG
    Now on to the bike that popped up mid summer.
    A friend of mine had sent me some pictures of a 1970 Suzuki T-250 II Scrambler and said it could be had very cheap if I was interested.
    You know I couldn't pass on it. Hell, it's exactly the kind of bike I like. Let's see... 70's, scrambler, 2-stroke, candy blue, what's not to like.:photog
    20160817_105852.jpg
    20160817_105953.jpg
    20160817_110019.jpg

    The owner was a friend of a friend. I gave him a call and a deal was made.
    #19
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  20. more koolaid

    more koolaid Been here awhile

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    1st bike up.. 1 page.....I know your happy to be back....but you may want to pace your self:rofl
    #20