THE SPECIAL TOOLS FOR SUZUKI GT250 RESTORATION

[TJCOOL]

I'm looking for a place I can pick up the tools required to do my total rebuild...there seems to be a handful of speciality items I'm going to need.....any thoughts on where I can buy these things? I would imagine they are designed specifically to work on the suzuki's bike...

thanks

tj

[wavehog33]

I'm looking for a place I can pick up the tools required to do my total rebuild...there seems to be a handful of speciality items I'm going to need.....any thoughts on where I can buy these things? I would imagine they are designed specifically to work on the suzuki's bike...

thanks

tj

What special tools are needed?? I have restored many and haven't needed any Suzuki tools yet??

[TJCOOL]

like crankcase separator, fork tools..sort of thing

[Vintageman]

The gt250 cases split vertically. No special tools needed. If you want to rebuild the crank then special tools, but most guys sub this out. To remove the clutch basket some guys get a simple special tool so far I have been able to get this done many times without special tool reliably. It would be nice to have or make that tool but still not a show stopper if you are impatient and too lazy too make or order like me... trivial task.
As of recent we have mentioned phillips or JIS. But so far I have not need this either and don't strip, but may get JIS. Else take the Phillips #2 or #3 and use a small sharp file to lessen the inside curvature between the +. Impact driver may be a must else you will Fup those screw heads for sure. Measuring tools are always nice but even feeler gauges and verniers can tell you a lot.

dig in

[akendall1966]

Having busted the clutch basket the tool to lock it is far cheaper than a used basket. You don't need it but, it's good insurance against having to track down a replacement. EBC used to sell them.

[TJCOOL]

EBC?...what is that clutch tool you refer to?

I plan on changing bearings and seals on the crank and transmission..is that considered a rebuild that would need subbing out?

[akendall1966]

http://ebcbrakes.com/product/ebc-clutch ... val-tools/
Allows you to hold the clutch still while undoing the nut that hold it on the transmission input shaft.

[TJCOOL]

i know what you mean now....yes I must get one of those for sure...

[Vintageman]

i know what you mean now....yes I must get one of those for sure...

Ah you are hurting my feelings . if I ever break one I'll i come back and say you were all correct. I am the guy who also puts Mikuni round mains in needle jets designed for Hex mains and will tell you to do the same

Thanks for the EBC link. Maybe someone will buy me one for Xmas present

Having the correct tools is always best.

the only thing you need to sub out is the crank. Please don't just change seals. at min buy new big end rod pins and big end cage roller bearings even if the say OK. There is a lot of heat generated here, it is a bit small dia to start and best to change so perfectly smooth. Not too costly. I would only buy OEM.

A good test to do is con rod side shake test. Here is where I say verniers (with a tail) is good enough tool (better to have dial gauge with feeler and a stand, but if you are skilled you can get a good reading with the verniers.) If side shake is ~ only 1/2 half the max (max is 3mm?) then the rods if not rusty or rust stain stiped are very good. Check at different crank angle. Then change seals new new big end pin and cage rollers minimum (ask to get old ones back and you'll see what I mean). The shop will let you know if anything else is needed. If rod has large side shake get con rods just so you have long crank life ahead of you particularly if you run higher rpms which you will do when only a 250 to start.

fun stuff

[TJCOOL]

sounds like it should be subbed out...I have no idea where I would find someone like this skilled enough to do this type of work....there never seems to be a lot of skilled workers in Ottawa from what i have seen...especially this sort....any ideas where I could send the crank for a complete over haul?...someone thata knows exactly what do do with an OEM suzuki crank...

thanks

Terry

[abotech]

Highly recommend Bill Bune, Crankmaster.

[TJCOOL]

Highly recommend Bill Bune, Crankmaster.

thanks..i have contacted him..

[MikeG]

Having busted the clutch basket the tool to lock it is far cheaper than a used basket. You don't need it but, it's good insurance against having to track down a replacement. EBC used to sell them.

I welded a little handle onto an old clutch plate, it works great

[TJCOOL]

Having busted the clutch basket the tool to lock it is far cheaper than a used basket. You don't need it but, it's good insurance against having to track down a replacement. EBC used to sell them.

I welded a little handle onto an old clutch plate, it works great

yes, I guess that would to...can you show me some pics please? I'd like to see exactly what you did...I was thinking of getting a little welding kit for myself...there are times when something like this would be very useful to have..

thanks

tj

[markush]

Hi!

Here the self made special tool I use at GT250.
Clutch tool: made with two plates.
Piston pin pusher: made of the upper part of a two arm puller and some extra parts.



Markus