Suzuki 2 Strokes

Test fit of right-side T500 rearset with trial adapter bracket made out of paper.
Not quite as clean looking as left side — gap between bracket & adapter is filled by a nut + ~ 2 washers.

can't you cut the threaded boss (r/h side of picture) off the frame and re-attach it where the footrest r/h bolt sits?

The left rearset attachment point is the stock mount for the muffler & passenger foot peg.
The right rearset attachment point is one of the 2 stock mounts for the driver foot peg.

We thought about the different options.
Went with a no-weld solution that allows us to reinstall the stock driver foot pegs.

But, thanks for your suggestion.


Next step is to look at how the Higgspeed exhaust will affect this solution.
Then the drawings are off to the water-jet-cutter shop.

Is it possible to insert a threaded insert into that frame tube to match the new peg bracket that won't interfere with going back to stock should you so choose?

I had a similar issue with the Dunstall because I needed to fit rearsets with no modifications to the stock frame. Quite a challenge.

Am not sure what you are referring to.
The 2 frame locations that I’m using are already threaded.

Now waiting with end in sight.
Parts are at painter & powder coater.

Will make a custom wiring harness.
Any suggestions on where to get wires with the stock colors?

Could you get the water jet cutter to make a new mounting plate with a big enough hole in it to go over the front lug? One bolt would hold it in place then. Your brake cable stop on the frame looks way out of line with the puller hole on the lever?

Interesting idea - hadn’t thought of that.
My final adapter drawings are at the water jet cutter shop. Now just need to order wire + some little odds & ends parts.
We’ve talked about going with a single piece design at some point down the road. Will keep your suggestion in mind.

This is my first foray into CAD software + digital machining.
Was pleasantly surprised at how easy it is.
Have two other items I’m working on: a bracket for a CL450 exhaust, and an underseat bracket to hold the battery + taillight on the GT250 cafe.

The water-jet-cut adapters turned out nicely:


Parts are back from the painter & are looking good.
Powder coater should be done this week.

This is our first build & we are on pins an needles.

Parts back from powder coater & looking spiffy.

Found really useful instructions for spoke wheel lacing on the GS forum:
http://www.thegsresources.com/_forum/sh ... sxs+spokes

And the results with NOS spokes:

Making more headway.

Mounted new Avon RoadRiders.
Its the third set we’ve done with a No-Mar CH200 tire changer. It has a bit of a learning curve — we are getting faster & got these tires on without marking up the powder coating.

Those wheels and tires look great!

Making some good headway.


Test fit of salty_monk’s adapter + a Kawasaki Concours twin-piston caliper.

Test fitting the spiffy new Higgspeeds.