Suzuki 2 Strokes

My 1973 GT250 had bad crank seals & has moved on to a new owner. Also pulled my 1972 GT550 project bike out of storage.
We are doing cafe builds of both bikes. The GT250 is up first & here are the pics.

1973 GT250 before the crank seals went bad.


Working on the motor.


Painting the crankcase.


Test fitting a Hotwing Glass RR1 seat. Will use a 1972 T250 tank painted a nice blue.


Fun with cutting tools. Removed the center stand brackets, detabbed the frame & made cuts for a future frame loop.

Nice... I have the same seat/tail on my GT250 cafe...they're nice...

Tom Garcia wrote:Nice... I have the same seat/tail on my GT250 cafe...they're nice...

How did you mount your seat?

jabcb wrote:

Tom Garcia wrote:Nice... I have the same seat/tail on my GT250 cafe...they're nice...

How did you mount your seat?

I have an aluminum pan under the seat hump that holds a sealed battery and the electrics



Where the kick up is under the seat cover, the aluminum pan has two holes (just above the battery). Rubber grommets go in these holes to take up the "play"... I put some bolts through the seat pan with nuts on the back (underside) that form two "pins". To put on the seat, nose is up and the two "pins" are inserted into the two holes on the front of the battery pan...




Once hooked in the rear holes, the nose of the seat is swung down to the frame top tubes. Two more bolts/nuts form pins under the front of the seat cover. These go through two holes in a frame crossmember shown here..



Once on, nuts are screwed on the front "pins" and they hold the seat down. The last pic shows the black foam strip I used on the top frame rails to keep the seat from rubbing... I couldn't find a pic of the seat underside with the pins but I can take on if you want to see that...

Tom

I like your aluminum pan. What size battery is that?

We will be using an AGM battery, Tympanium rectifier/regulator & all LED lighting.

We were thinking about using a sheet of black HDPE. The HDPE would be attached to the frame & the seat would be attached to the HDPE.
HDPE is easy to work with & is available in a variety of sizes at Graingers.

Making some headway with the rebuild.

Found an interesting forum post of a GT250 cafe build in Australia.
http://canberrariders.org.au/forum/inde ... 53/page-15

He made rearset mounts that used two existing frame attachments.

Making headway slower that I was expecting.

Motor will be all black except for carbs & polished case covers.
Ordered the Higgspeed chambers.
Have the K&N tapered pod filters with rubber end cap. (# R-1070 + the filter wrap)

Stock main jets are 112.5 & we are going up 10 to 122.5
Let me know if you experts think this isn’t enough.

Motor is mostly assembled & we are now polishing the case covers:

jabcb wrote: Ordered the Higgspeed chambers.

Make sure you factor in additional time waiting for those chambers. I was told 6-8 weeks when I ordered them. Waited 13 weeks to finally get them.

Hoping the project will pick up speed soon.

Its just about 8 weeks since we ordered the Higgspeed chambers.
Just ordered rearsets.
The K&N tapered pod filters didn’t work out, so we switched to the angled version.
Got a custom oil tank similar to the one member sbaugz has.
Frame is at the welder shop.

You would have had Jemcos in about 10 days. Just sayin'.........



Lane

rngdng wrote:You would have had Jemcos in about 10 days. Just sayin'.........



Lane

A few years ago I got Jemco pipes for my GT750 & they did show up fairly quickly.

A forum member looked into Jemcos for the GT250 & was told they were designed more towards racing.
viewtopic.php?f=21&t=9440&p=139488&hili ... co#p139488

There be Higgspeeds here.

Making a bit more headway.

Did a spiffy job at polishing the engine covers & fork lowers. (We cheated & had forum member Sandman do the work.)
A few parts are at the painter.

The T500 rearsets are here — now need to figure out how to adapt them to the GT250.
Once we got that figured out, then the fame + wheels are off to the power coater.

Test fit of T500 rearset with trial adapter bracket made out of paper.