Suzuki gs125 + top end rebuild

[at106]

I thought it was about time i got some pictures up of my suzuki gs125 project. I bought it off a member for £120 with a lot of spares including an engine and frame. In the past month or so i've stripped it down and begun rebuilding it to a road worthy state.

This is the only picture i took before completely stripping it down. I do also have the tank, seat and bodywork.
https://i448.photobucket.com/albums/qq202/at106/PICT0001-42.jpg
As you can see it wasnt in great condition.

Unfortunately i didnt get any pictures of the "restoration work" i did on it, just final pictures. The major job was deciding what to do with the frame, swingarm and stands. They all had surface rust, ideally i would of had them shot blasted and powdercoated however the best price i could get this done locally was around £160, but as this is a budget build i used a wire brush and hammerite smooth.

To remove the old paint and loose rust i used a blow lamp and a wire brush drill attachment this made the old paint come off easily but it still took many hours.

Then i cleaned the parts with water to remove any dust. After they dried i painted on methylated spirits and left it to evaporate to remove any traces of oil.

Then i could finally start painting, i started with the stands as the finish didnt matter so much. I found that two thick coats were enough to provide a good finish, but if you apply too much the paint will run. Below are the finished parts
https://i448.photobucket.com/albums/qq202/at106/d.jpg
https://i448.photobucket.com/albums/qq202/at106/f.jpg
https://i448.photobucket.com/albums/qq202/at106/frt.jpg
https://i448.photobucket.com/albums/qq202/at106/g.jpg
https://i448.photobucket.com/albums/qq202/at106/h.jpg
https://i448.photobucket.com/albums/qq202/at106/t.jpg
https://i448.photobucket.com/albums/qq202/at106/rd.jpg
If you look closely the finish isnt great but for £20 it isnt bad, and hopefully it'll last.

Next step was to fit the forks. While the bike was apart i emtied the old oil and polished the lowers. I forgot to rotate these pictures so they're sideways!
https://i448.photobucket.com/albums/qq202/at106/bvh.jpg
https://i448.photobucket.com/albums/qq202/at106/hg.jpg
https://i448.photobucket.com/albums/qq202/at106/tt.jpg

Then i fitted the swing arm and i loosely fitted the shocks. Unfortunately they're decent shocks (hagon) but they've been badly looked after so they cant be reused, unless anyone knows how to rebuild them?
https://i448.photobucket.com/albums/qq202/at106/tyt.jpg
https://i448.photobucket.com/albums/qq202/at106/tee.jpg

I did also get the engine and wheels fitted however there are no pictures as i managed to break the camera

However there is a possible problem Today i decided to remove the oil pump gauze thing to clean it and in it there were lots of what appeared like flaky paint and some small metal filings. But my biggest concern is that there was a 1/2 washer sat underneath the gauze. It's been made as a 1/2 washer but i dont know where it could be from, i'll try and get a picture of it.

That's it for now, hopefully i'll get another camera sorted and have some updates on monday.

[N cee thirty]

[at106]

Haha thanks

I've now got a bad picture of the washer, it measures about 27mm outer and 23mm inner diameter.
https://i448.photobucket.com/albums/qq202/at106/021.jpg

[The Artist]

Luckily you picked the best 125 in the world to work on.

[at106]

[The Artist]

I know the gs's wiring loom quite well so if you are wondering where something connects, post a picture and I will try and identify.

[at106]

[at106]

I've now got all the electrics fitted and working, i've also had the engine running I would get some pics but it's currently raining Now all i need to do is tidy up the wiring and fit a few small parts.

However i need the rubber part which connects the airbox to the carb so does anyone have one or know where i can get one?

[pepperami]

Pics or it did`nt happen!
____________________
I am the sum total of my own existence, what went before makes me who I am now!

[at106]

[von1papen]

Not a GS obvs but the Honda CG head n tail lights will only work when its running (had us stumped when initially rebuilt!)

[The Artist]

[at106]

The battery is 12v 7ah

[The Artist]

Lights and stuff should work when the engine isn't running.

[UnspeedySam]

Looks like a cool project. Although my RXS is in a significantly better condition I want to do something similar. I have until about March to get it ready for my girlfriend after she gets her CBT.

Might have to buy myself a drill to save wire brushing off all the old paint by hand...we'll see how patient I am...
____________________
Riding: BMW R1150RT `02 bought mildly crashed
Fixing: Also the BMW as I get less broken bits
Gone: ZZR600 '00, TRX850 '97, RXS100 '93, JS125-6B '07, BMW R1100RS '93, Kawasaki ZX-6R-J2 '01, Honda Bros NT400 NC25 '88

[at106]

[at106]

Small update, spent around £100 for most of the parts required to complete the bike. And i've now managed to get hold of the airbox intake rubber (It did cost £18!) However now the bike wont start It's got compression, spark and fuel is reaching the cylinder, hopefully i'll get time tomorrow to take a look at it.

[at106]

I finally managed to get somewhere with the bike
After it failing to start i noticed it was leaking some oil from the engine head gasket so ive now sealed that correctly and reset the valve clearances. I also connected the battery directly to the wiring loom instead of using jump leads and it started really easily.

I then set about tidying up the wiring, the right side of the bike looks pretty neat now. Apart from the rusty exhaust but it's going to stay like that because ive heard high temp paint is unlikely to stay on.
https://i448.photobucket.com/albums/qq202/at106/IMG00057.jpg
https://i448.photobucket.com/albums/qq202/at106/IMG00056.jpg

I then tidied up the left side, obviously the wires will be hidden by the fuel tank.
https://i448.photobucket.com/albums/qq202/at106/IMG00059.jpg
https://i448.photobucket.com/albums/qq202/at106/IMG00058.jpg

Next i fitted all the bodywork to see how it looked, from a distance it looks ok but up close the previous owner has badly painted the tank and plastics. I was hoping i would be able to just touch up the bad parts but i think it might need a full respray However i'll try some T cut on it first and see what happens.
https://i448.photobucket.com/albums/qq202/at106/IMG00064.jpg
https://i448.photobucket.com/albums/qq202/at106/IMG00060.jpg

I also managed to fix the lighting problem, it turns out one of the connectors was damaged so that's now sorted

Ive just got a new seat for £20 delivered next to do is,
Fit the new rear shocks
Fit new front brake pads and bleed brake brake
Sort out the sidestand spring
Buy and fit new tyres
And torque up the handlebars

Does anyone know what type of headlight bulb this bike takes?

[tvchimp]

BA20D bulb.

Best place is probably ebay, all the same apart from the xenon ones which are brighter (i know, have used the standard vs. xenon ones).

I've used this supplier before for bits and they're quick delivery and packaged well so shouldn't be broken when you receive it..

https://www.ebay.co.uk/itm/H6M-BA20D-395-XTREME-WHITE-XENON-MOTORBIKE-35-35W-BULB-/220656857279?pt=UK_Motorcycle_Parts&hash=item33602c70bf


nice looking bike
____________________
Bike: Currently Bikeless... Gahh

[at106]

[at106]

Managed to get some work done on the tank today. First job was to remove the lock as i didnt get the key for it. That was much more difficult than expected! I then set about stripping the paint off the tank. And revealing the original blue.

https://i448.photobucket.com/albums/qq202/at106/IMG00093.jpg
https://i448.photobucket.com/albums/qq202/at106/IMG00092.jpg

Hopefully i'll get that finished saturday and prepped for painting. After some experimenting i've decided to use hammerite smooth black seing as i've still got half a tin. I discovered if you paint it on leave it to dry then use wet and dry it comes up pretty good, then i'll use halfords petrol resistant lacquer.

I also fitted my new shocks today aswell as the headlight bulb.

[The Artist]

[at106]

[at106]

Thought id update this a bit as i havent posted for a while. I've had quite a bit of time to work on the bike but dont seem to have got much done

But today i managed to shorten the wiring loom so i could fit the headlight and i also fitted the headlight.
I've now also painted and smoothed the tank, and it looks suprisingly good. I'll get some pictures at the weekend. Now i just need to apply suzuki decals and lacquer it. But i'll wait for some warmer weather to do that.

I've also polished the body panels using T cut and they actually look good, so i wont have to repaint them

Does anyone have a picture of how the front brake pads and clips are ment to go together?

Thanks

[at106]

Pictures as promised
Front view showing the headlight fitted, however today i discovered that main beam is brighter but points lower than dipped beam so i need to sort that tomorrow.
https://i448.photobucket.com/albums/qq202/at106/IMG00122.jpg

New rear shocks from a ybr125 (i think) they bolted straight on.
https://i448.photobucket.com/albums/qq202/at106/IMG00123.jpg

Left side panel after a quick polish
https://i448.photobucket.com/albums/qq202/at106/IMG00124.jpg

Fuel tank painted with hammerite. It still needs suzuki decals and lacquer applying then hopefully it'll shine
https://i448.photobucket.com/albums/qq202/at106/IMG00126.jpg
https://i448.photobucket.com/albums/qq202/at106/IMG00127.jpg
https://i448.photobucket.com/albums/qq202/at106/IMG00128.jpg
https://i448.photobucket.com/albums/qq202/at106/IMG00129.jpg

Sorry for the bad pictures