Under an old house in Queensland - The Suzuki GT250 and other bikes that belong on the scrap heap!

Discussion in 'Some Assembly Required' started by Damian_74, May 9, 2019.

  1. Damian_74

    Damian_74 Been here awhile

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    The parts available for the Jawa 350 is amazing - between Czech new production, Indian Yezdi copies and other pattern parts; so far there isn't anything that I can't easily get NEW.
    Even the Velorex side car is still in production with a good parts department.

    Comparing this with the resto's on my fleet of Suzuki 250 two-bangers - something that I an sure you are going through with your T500 rebuild.
    There is always one or two parts that you made form unobtanium.
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  2. Damian_74

    Damian_74 Been here awhile

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    Suzuki GT250L Seat

    Finally home after far too long at sea...........a few of my orders have arrived......some still stuck in the COVID backlog (got to stop selecting the tight ass option for freight).

    I've got all the bits to make this bike original but as I have a GT250B that will appease the rivet counters, I'm locking away the OEM bits and giving this bike a slight Café look.

    Found a mob in Vietnam that makes reproduction seats (good OEM seat is now bubble wrapped and boxed).
    Had to make a few very minor trims to the seat mounts to get it to fit correctly but overall happy with the quality - and the price was reasonable.

    1973-1978 Suzuki GT250 solo low profile cafe racer motorcycle seat saddle SKU: T8222 - Texavina

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  3. 3legs

    3legs Real men ride sidecars Supporter

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    Someones a happy kid :D
  4. Damian_74

    Damian_74 Been here awhile

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    Suzuki GT250L - Tyres

    It is now off the work stand and resting on its new shoes - have possibly over-tyred it.
    Fitted Avon Road-raiders MkII. Soft and sticky and definitely going to outperform the suspension and rider.

    Front 100/90-18 (in retrospect should have gone with the 90/90-18. It clears everything but it's dam tight!).
    Rear 110/90-18

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    My new exhaust is still sitting with Customs in Sydney - two weeks and they haven't moved - no mater how many times I check the tracking!!!!!!!!!!!!!
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  5. Damian_74

    Damian_74 Been here awhile

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    Suzuki GT250L - Exhaust

    My pipes finally arrived from the UK.

    Not 100% happy with the fit - bit of a headache getting them to clear everything and be symmetrical.

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    Some re-drilling of brackets, bending of brackets and a few spacers and they are close enough.
    But they do look good!
    I'm not sure that they will get the same appreciation form the neighbours when I fire it up.

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  6. Damian_74

    Damian_74 Been here awhile

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    Suzuki GT250L - Rearsets

    Now that I have the exhaust I can try and work out where all the controls and foot pegs need to go.

    Started with the pegs - this is version #1.....the final product may be very different.

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    Trying to find that sweet spot between function, comfort and looks.....I fear that comfort will be the forgotten party.

    Many CAD (Cardboard Assisted Drawings) and plywood mock-ups and it's getting somewhere close.

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  7. Wildebeest90210

    Wildebeest90210 Long timer Supporter

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    They do look the part, are they Higgspeed?
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  8. sruss67

    sruss67 Been here awhile Supporter

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    Those pipes look spot-on for the build and suit the bike very nicely.
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  9. radmann10

    radmann10 Old fart Supporter

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    Damn, that bike looks very nice. My first motorcycle was a Suzuki 200 2cyl 2 stroke very similar to yours.

    Your post got me thinking, what bikes were available in 1954 lol?
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  10. Damian_74

    Damian_74 Been here awhile

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    Yes Higgspeed GP pipes.


    I do like the look of them - period correct.

    Doing what I can to make the bike a time capsule from the 70's.
  11. Wildebeest90210

    Wildebeest90210 Long timer Supporter

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    They have a good reputation for making good power from stock porting and good quality. Always difficult buying pipes from another country for fit, had to beat the crap out of a Pro-form pipe for a Husky, re-weld it and even then got a massive midrange flat spot !
  12. Damian_74

    Damian_74 Been here awhile

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    One of the main issues I've got with the Higgspeed pipes are the mounting nuts.

    The GT250 has castellated nuts that screw directly to the barrel. A horrid system, especially when a bike of this age has had too many monkeys working on it; the fine thread inevitability strips. An expensive fix requiring welding and machining of the barrel.

    The OEM exhausts have about 15mm of thread inside the castellated nut. Then take away 5mm for the exhaust joint (that usually compresses to 3mm) and there is 12mm of engaged thread.

    The Higgspeed pipes with a nut that looks like it was chewed out rather than manufactured has about 12mm in total. No room for an exhaust joint. I've found some copper washers that are 2mm thick to use as joints. Hope that they will seal. Might call for some red silicon.

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  13. Wildebeest90210

    Wildebeest90210 Long timer Supporter

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    Not great at all! Look more like they've been chewed by a bear......
  14. Scrivens

    Scrivens Long timer

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    That's a "vice-grip ready" nut.
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  15. 3legs

    3legs Real men ride sidecars Supporter

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    I was just going to say " I don't remember making any exhaust nuts for you " :lol3:lol3:lol3

    Geez that is rough.
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  16. Damian_74

    Damian_74 Been here awhile

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    Suzuki GT250 - Brake linkage and Bell Crank.

    I want to retain the feel and ratio of the OEM rear brake pedal. I'm using the mounting point for the OEM brake lever and fitting a Bell Crank that will be operated via a linkage.

    Started with a billet of 50mm 6061 and made a few ally chips in the 4 jaw.
    There is a bit of waste with material this size but it was in stock.

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    Fitted a Delrin (Acetal Plastic) bush with a 0.25 interference fit and then machined it after fitting to give a 0.15mm running clearance with the original brake leaver pivot.

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    Mounts next - need more aluminium..............
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  17. Wildebeest90210

    Wildebeest90210 Long timer Supporter

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    That looks nice, plenty of ally left under the lathe!!!!
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  18. Damian_74

    Damian_74 Been here awhile

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    Just for you Wildebeest.....................and yes there was some serious cleanup needed!

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