GT250 Cafe - Build Experiment
Moderators: oldjapanesebikes, H2RICK, Suzsmokeyallan
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- To the on ramp
- Posts: 334
- Joined: Sat Jan 10, 2009 2:58 pm
- Country: USofA
- Suzuki 2-Strokes: GT250 x 2, GS1100E
- Location: Parma, Ohio
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
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
83 GS1100, 74 H2, 76 GT250 Cafe, and 72 GT250
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- AMA Superbike
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- Location: Blythewood, SC, USA
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- To the on ramp
- Posts: 334
- Joined: Sat Jan 10, 2009 2:58 pm
- Country: USofA
- Suzuki 2-Strokes: GT250 x 2, GS1100E
- Location: Parma, Ohio
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
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
83 GS1100, 74 H2, 76 GT250 Cafe, and 72 GT250
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- To the on ramp
- Posts: 334
- Joined: Sat Jan 10, 2009 2:58 pm
- Country: USofA
- Suzuki 2-Strokes: GT250 x 2, GS1100E
- Location: Parma, Ohio
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
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
83 GS1100, 74 H2, 76 GT250 Cafe, and 72 GT250
- water cooled
- Yeah Man, the Interstate
- Posts: 704
- Joined: Thu Oct 23, 2008 3:23 pm
- Country: USA
- Suzuki 2-Strokes: 1974 Suzuki GT750
- Location: Medina OH
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?
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?
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- To the on ramp
- Posts: 334
- Joined: Sat Jan 10, 2009 2:58 pm
- Country: USofA
- Suzuki 2-Strokes: GT250 x 2, GS1100E
- Location: Parma, Ohio
The basket rides on the clutch gear bushing as in stock...water cooled wrote: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?
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...
83 GS1100, 74 H2, 76 GT250 Cafe, and 72 GT250
- water cooled
- Yeah Man, the Interstate
- Posts: 704
- Joined: Thu Oct 23, 2008 3:23 pm
- Country: USA
- Suzuki 2-Strokes: 1974 Suzuki GT750
- Location: Medina OH
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- To the on ramp
- Posts: 334
- Joined: Sat Jan 10, 2009 2:58 pm
- Country: USofA
- Suzuki 2-Strokes: GT250 x 2, GS1100E
- Location: Parma, Ohio
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- To the on ramp
- Posts: 334
- Joined: Sat Jan 10, 2009 2:58 pm
- Country: USofA
- Suzuki 2-Strokes: GT250 x 2, GS1100E
- Location: Parma, Ohio
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- Around the block
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- Joined: Thu Dec 11, 2008 5:00 pm
- Location: San Francisco, CA
- Contact:
Injector Oil Tank
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.
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.
Kevin R. Walsh '75 Suzuki GT-250 Cafe Racer
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- To the on ramp
- Posts: 334
- Joined: Sat Jan 10, 2009 2:58 pm
- Country: USofA
- Suzuki 2-Strokes: GT250 x 2, GS1100E
- Location: Parma, Ohio
Re: Injector Oil Tank
I ordered it online at www.usplastic.com.... .25 liter not 1/2 pint.... Here are the catalog numbers and prices...krwalsh wrote:Where did you get the injector oil tank?
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
83 GS1100, 74 H2, 76 GT250 Cafe, and 72 GT250
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- Novice racer
- Posts: 947
- Joined: Sun Aug 23, 2009 7:59 pm
- Country: USA
- Suzuki 2-Strokes: gt750
- Location: HOUSTON USA
oil tank
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
i dont know how far a 1/2 pint of 2stroke will take you.
just curious .
and i love the paint scheme.
mark
She will never be pretty but hoping she will be a fun ride.
1973 SUZUKI GT750K.=SOLD
yamaha speedtwinn 100 barn find =SOLD
1x 1973 kawasaki H1 (restored)
1x 1973 kawasaki H1 (basket case) =SOLD
1982 HONDA CB900F =SOLD
1982 YAMAHA RD350LC.
1985 RZ350N
1973 SUZUKI GT750K.=SOLD
yamaha speedtwinn 100 barn find =SOLD
1x 1973 kawasaki H1 (restored)
1x 1973 kawasaki H1 (basket case) =SOLD
1982 HONDA CB900F =SOLD
1982 YAMAHA RD350LC.
1985 RZ350N
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- To the on ramp
- Posts: 334
- Joined: Sat Jan 10, 2009 2:58 pm
- Country: USofA
- Suzuki 2-Strokes: GT250 x 2, GS1100E
- Location: Parma, Ohio
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
Tom
83 GS1100, 74 H2, 76 GT250 Cafe, and 72 GT250
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- On the street
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- Joined: Wed Oct 22, 2008 6:31 pm
Favorite topic of all time
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.
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- To the on ramp
- Posts: 334
- Joined: Sat Jan 10, 2009 2:58 pm
- Country: USofA
- Suzuki 2-Strokes: GT250 x 2, GS1100E
- Location: Parma, Ohio
Re: Favorite topic of all time
Brett Kerby wrote: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
83 GS1100, 74 H2, 76 GT250 Cafe, and 72 GT250