Suzuki 2 Strokes

Having documented the trials and tribulations of the "JB Weld" Special on the KTW board. I've decided to expose my personal pain and suffering in the build of a 76 GT250 cafe... We'll see how this goes...

Take a seat because this may take a while.....

This bike started as a freebie score within 30 minutes of posting an ad on the Atlanta Craigslist for "Wanted - 60/70s Japanese Two Strokes". Upon arriving for pickup I found the front tire off and the bike outside for THE LAST 15 YEARS... Oh well, it's free...RIGHT? Anyway the thing had sunk down into the Georgia clay up to the middle of the side covers. The plywood and shingle overhang that originally protected it from the environment long ago ceasing to function... I wish I would have taken some pics when I got it home. Salvaged engine, frame, hubs and tank. The pipes and rims were completely rotted through in MANY spots.

So, I've been collecting some tidbits during the previous 9 months of being stationed somewhat temporary in Ohio. Previously posted under another thread was my first effort in respoking since my 10-speed days. Thanks to Lane, TZ375, and a new truing stand, I think they are right - AND ROUND (Yes Lane - they really are). The hubs were polished prior to assembly - again using hints found here and on the KTW board. Rims are 18 x 2.15 front and 18 x 2.50 rear - Moose aluminum via Dennis Kirk. I can dig up the part numbers if anyone is interested...








I also had a local sandblaster go over the frame - Cost $39.85 out the door... Way less than I though it would cost... After cutting and grinding off the brackets and handles I didn't think I would need (but am assured I will later) it got some zinchrom primer and some gloss black.

Also mounted 100 and 110 BT45s on front and rear respectively...








I will also post this in the tech portion of the board separately:

If you need replacement forks for a GT250 but don't care about them being original, try a set off a Hond* CMX250 Rebel... They are the same diameter as the GT forks and the axle diameter is exactly the same as the GT as well... No shims, special bearings, or else to adapt the wheel to the fork lowers...NA-DA...

Tom

Hey that's a good start. Clean from the ground up!!

Here's my truing stand. I used the stock axle. I cut a piece of scrap PVC to make up the length so I could tighten the axle nut. Then I just clamped on the PVC in the vise. The anvil section of the vise made a perfect surface for my mag base and indicator. Spoke wrench is that goofy looking black thing at about the 9 o'clock position. Not as sexy as a real truing stand, but it works fine.

Coyote wrote:...but it works fine.

In the end....that's all that matters!

Tom, That's looking good.

Tread on that 100 section front BT45 sure wraps a long way around, even on a 2.15 rim. I'm surprised how far around it goes. I guess it doesn't matter how far over you lean, it will never run out of tread.

tz375 wrote:
Tread on that 100 section front BT45 sure wraps a long way around, even on a 2.15 rim. I'm surprised how far around it goes. I guess it doesn't matter how far over you lean, it will never run out of tread.

It might be more optical illusion than reality... I just mounted up the tires... They still need to have air put in, seat the bead, etc in the pics...

Seated the beads on the tires today TZ so here are a couple pics to check profile/contour... Look any better?

Tom

Nice, Tom. The wheels look great.



Lane

A little more work with the CMX250 Rebel forks and axle...even the Rebel spacers worked... GS1100 front disc... Still waiting on the sprocket carrier bearing from Motorcity... Ordered sprocket today (Thanks Lane for the supply lead)... Waiting for the Redwing rebuild kits to arrive in the mail... Oh well! Maybe next weekend...a roller....

Tom,

Looks great...hope to see it in person soon! I'll give you a call...

Kevin

Front end sorted with the stock CMX 250 Rebel dual-piston caliper after reducing the diameter of the GS1100 rotor... Bolts right on.... And HH pads are available for the caliper...

Was playing with the rearset mockup today... It will come out perfect (I think) using the stock front peg mount and a special over-the-counter setup for the swingarm pivot bolt.....

I picked up the rearsets for $14.58 with shipping. DOES ANYONE KNOW WHAT THEY ARE FROM?????

McMaster Carr had 9" end-threaded studs with hex reducer bushings... Large hole on one side to tighten the swingarm and a 3/8-16 hole in the other for the allen cap screw (upper mount).

The stock front peg mount is threaded 10mm x 1.25 so the two cap screws are relatively the same size....






The two mount points line up dead on for the original rearset mounting holes... (used rear axle adjuster bolts slipped in)






Here from the side I think they might be angled down slightly from what they were on the stock bike... (ANYONE FIGURE OUT WHAT THEY ARE FROM YET? I DON'T KNOW)




Still have to polish the rearsets... Did polish the sprocket in about 45 minutes...

LANE - Thanks for the hook-up with Sprocket Specialists....





Thanks for all the help and constructive criticism.....

Great work Tom. I always look forward to your updates.

Tom , the rear sets look a lot like the 04-05 GSXR600 http://cgi.ebay.com/ebaymotors/04-05-GS ... ccessories

Suzukidave wrote:Tom , the rear sets look a lot like the 04-05 GSXR600 http://cgi.ebay.com/ebaymotors/04-05-GS ... ccessories

Dave - I think you are right.... I grabbed the right set and it looks EXACT...

I know I search the site (and KTW) to see what others have done, what works, what doesn't, etc... That's my intent with this thread...

Now another piece of the puzzle is solved... THANKS DAVE!!!!!