GT250 Cafe - Build Experiment

[Tom Garcia]

Had more issues with the second go at painting the fiberglass seat/tail...the base color would crack and the primer turned to goo underneath... Same primer and base used on the tank and it was ok??????? Took it back down to the glass and reprimered with two-part Evercoat Feather Fill... This stuff is supposed to be great....

Started machining the Clutch spacer...milled the bosses off the back of the basket...and roughed in the cylinder heads on the lathe....

I'll be back at the shop in the morning to try and finish up...

Hopefully it will warm up this week enough the paint...

Tom

[rngdng]

The intakes are HUGE!!!!!! It looks great; can't wait to ride it.



Lane

[Tom Garcia]

Ok... More fun today in the shop...still have all my fingers...not even any blood shed...

Got the steel spacer machined that provides room for the seal andprovides the nice surface the seal lip rides on. The bore of the gear is opened up to 4.5 inches to accept the spacer OD...



Machined the aluminum ring that the seal seats into that will be welded into the side cover....



The OD of the basket was turned down a tiny bit to seat concentrically into a matching shallow recess in the steel spacer. All the sandwiches together in the cover....



And from above....



Now to fire up tHe TIG...

Tom

[Tom Garcia]

Finally got all the machining done for the clutch.... Everything bolts together nicely with the spacer in between... 10-32 allen flat heads...





Cut an o-ring groove in the face of the clutch gear...hopefully that will limit seepage...



Also jigged up the aluminum ring that holds the seal with the side cover. Got a little of the TIG welding done including plating in the gap between the rear side of the ring and the cover. I'll finish up the front tomorrow because I need to work it around the crank gear retaining nut...



Also FINALLY got the white basecoat to lay down on the glass tail... THANK YOU JESUS!!!!

Have the blue topper on but need to paint the black stripe and clear tomorrow... Hopefully the weekend will remain productive....

Tom

[water cooled]

Tom,

That looks like great progress. The clutch basket assembly is coming out really nice. Does that basket ride on a bushing or needle bearing? Separately, how hard is it to get fork seals and the top (rubber) boots for the 250?

It looks like your coming down the home stretch. Do you have ideas on where to start on the jetting?

[Tom Garcia]

Tom,

That looks like great progress. The clutch basket assembly is coming out really nice. Does that basket ride on a bushing or needle bearing? Separately, how hard is it to get fork seals and the top (rubber) boots for the 250?

It looks like your coming down the home stretch. Do you have ideas on where to start on the jetting?

The basket rides on the clutch gear bushing as in stock...

I know that stock seals and the accordion boots were available from Motor City Powersports (dealer) a while back. I need to order a set for the daughter's 250. I just looked in my NOS boxes thinking I had already got them but am mistaken... Problems with yours?

No idea on the jetting..I don't know how many 250's are set up with 6-petal reeds and 36mm Lectrons. From what I hear, it should be easier with the Lectrons. But then again, I SUCK at jetting... Aylor did 99% of the jetting work on the H2 at the Gap...

[water cooled]

The right fork seal is weeping. It takes several days to see a little oil but then again, the forks are not seeing any dynamic pressure spikes from riding so I am not comfortable leaving them the way they are. I also need to get the small rubber caps for the forks. Mine were brittle and cracked.

[Tom Garcia]

FINALLY! Success in painting that blasted tail!!!!!! Luckily got finished before the torrential rains hit...










Picked up this nifty 1/2 pint injector oil tank....

[Tom Garcia]

Stuck the heads on for a dry run on compression..

[krwalsh]

Where did you get the injector oil tank? I modified a tank from an oiler on a machine tool, but something smaller I could tuck under the tail would be nice.




It is nice because it is clear, and have a neat little spring-closed flip door, but smaller would be nice.

Also, I'm sure you've thought of this, but your kick-starter is worthless with the left hand peg where it is. You might want to move them back to the rear pipe mount position, or count on a lot of bump starting.

[Tom Garcia]

Where did you get the injector oil tank?

I ordered it online at www.usplastic.com.... .25 liter not 1/2 pint.... Here are the catalog numbers and prices...

Tank 8787 $8.63
1 5/8" Cap 8929 $1.52
90 Degree Fitting 64479 $0.54

Thanks for the head-up on the kickstarter....

Tom

[two-stroke-brit]

hey tom what do you think will be the range of use for the tank in miles,
i dont know how far a 1/2 pint of 2stroke will take you.
just curious .
and i love the paint scheme.
mark

[Tom Garcia]

As far as range on a quarter liter.... About one tank of gas... My current intent is to pre-mix a bit as well so I'll be going light on the pump. I won't be challenging Ironbutt Allen any time soon so if it will make it up and back at the Gap between fills I will be OK with that. My commute to work and back is about the same distance.

Tom

[Brett Kerby]

Just gotta say as a 250 owner this has been my favorite topic to follow thus far. I honestly check for updates everyday. Tom keep up the awesome work, it is very inspiring to say the least.

[Tom Garcia]

Just gotta say as a 250 owner this has been my favorite topic to follow thus far. I honestly check for updates everyday. Tom keep up the awesome work, it is very inspiring to say the least.

Thanks! I've learned a lot from this board and KTW...the fine group of members that is... Hopefully it will promote some ideas and prevent some people from making some mistakes I've come across...

Tom