GT200X5 Project

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Collected some more bits from Vapour Blasting this morning.

Fork legs blasted and brush finished / lacquered to as close as possible replicate the original finish.

Carbs blasted and rebuilt with all steel bits re-zinced.

Engine bits vapour blasted ready to receive paint.

https://i5.photobucket.com/albums/y164/BLUEX5/IMG_0101_zpsf52fc45c.jpg~original

https://i5.photobucket.com/albums/y164/BLUEX5/IMG_0102_zpsb499cd1f.jpg~original
____________________
18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Great progress, this is going to look really smart when finished.

How much did the vapour blasting cost out of interest ?
____________________
1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

chickenstrip · Super Spammer Joined: 06 Dec 2013 Karma :

Looking forward to seeing the finished job Blau. Always had a soft spot for 2 strokes and the X5 was a sweet little machine. Nice RDs too Thumbs Up

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Right last update this side of the new year (probably).

I wanted to achieve a rolling chassis so I could vacate the bloody thing into the shed without fear of damage. So I assembled and fitted the forks yesterday (new stanctions and seals). Then I added the fiddly shit (centre stand and footrest bar, plus NOS rear brake pedal, I hate shit with springs!). This morning I used by trusty workbench (rotten garden bench) to support the frame so I could refit the front wheel, then I hoiked the lot onto axle stands under the footpegs so I could refit the rear wheel and torsion bar. Slowly working my way through the stash of bits now.

So, rolling chassis -

https://i5.photobucket.com/albums/y164/BLUEX5/IMG_0109_zpsaf54e65d.jpg~original

https://i5.photobucket.com/albums/y164/BLUEX5/IMG_0107_zps26fd16ac.jpg~original

https://i5.photobucket.com/albums/y164/BLUEX5/IMG_0106_zps4a226e32.jpg~original

Now safely stashed away in the shed. Engine to clean up and refit next.
____________________
18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

Blue, that's looking immaculate so far!

You'll have it finished and ready for the show stand at Stafford in no time! Something that's going to look better than new needs to be shown at least once before you start racking up the miles/smiles IMO.

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Small update - I've been using the odd hour on a weekend when it's not pissing it down to do a few jobs. I managed to get the engine reassembled and back in the frame relatively painlessly over Xmas, other than the shitty clutch which munched one of my finger ends and caused much rage with it's stupid spring and pin construction.

I've used self amalgamating tape to repair the rough bits of the wiring harness cover, but other than replacing a couple of crimps it's actually in decent nick. It's now fitted to the bike and I've spent the odd hour the last couple of Saturdays routing it and fitting some of the electrical gubbins. Even having the factory manual doesn't make it the easiest job in the world, but I'm just about happy with most of it now.

https://i5.photobucket.com/albums/y164/BLUEX5/photo2_zps0b85bb32.jpg~original

https://i5.photobucket.com/albums/y164/BLUEX5/photo1_zpsc9257475.jpg~original

Did a few odd jobs this morning, fitting the washers I missed off the fork clamp bolts and mounting the rear indicators so I can "sign off" all the wiring to the rear of the battery box. In doing this I found that the rear light mounting is a bit on the floppy side despite the bolts being tight, so I assume the rubbers are shagged and have ordered some more. A million and one jobs I can do now, mount the exhausts, carbs and airbox, clocks etc, It's actually giving me a headache what to do next. Still, it'll be a couple of weeks as I have my GSXR1100 to service now.
____________________
18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

Mate if this is all together before 22/04, you really will have to bring her to Stafford. It could be the cleanest X5 in the country by the time you have finished. Smile

I want to ride my KMX whenever it's dry, but now I've decided to show it at Stafford in April I'm not going to risk getting it filthy or damaged before then.

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Groove · World Chat Champion Joined: 10 Feb 2005 Karma :

Going by the rate of progress thus far, my predicted finish date is actually the 22/04...2019.

Good work though, id love to do this one day.
____________________
|| Past: 1991 Kawasaki ZXR 250 ~ 2003 Honda CBR 600 F Sport ~ 2004 Kawasaki ZX6R B1H 636 ~ 1999 Yamaha R1 ~ 1999 Kawasaki ZX6R J ~ 2004 Kawasaki ZX6R B1H 636 ~ 1998 Honda VTR1000F Firestorm ~ K1 GSXR 600 Track bike ~ K6 GSXR 1000 ~ 2006 Speed Triple 1050 || Current: 2005 R1 https://www.adrucore.co.uk

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Just farmed out the rechroming of the front guard and centre stand handle bit, £95 plus VAT Shocked

Best quote so far for restoring the seat is £140.

Best advice I can give anyone is don't restore anything, ever.
____________________
18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

Fladdem · World Chat Champion Joined: 29 Jun 2011 Karma :

Cool!

My dad usedto have an x5 a few of years ago, when I was about twelve, that thing was a hoot on the back of it!

Should look really nice when it's finished. Thumbs Up

____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.

Clutchy · World Chat Champion Joined: 08 Nov 2011 Karma :

Sooooooooo clean! Drooling

____________________
Malaguti F12 Phantom-Dead, Suzuki AY50- Dead, NRG power DD LQ, CBR125.
*33 BHP restriction up on 10/12/14* Current bikes/car: SV 650 S/ MKIV GOLF
Guide to pass your test with no lessons!

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Busy day today as decent weather for once....

Clocks and switchgear installed -

https://i5.photobucket.com/albums/y164/BLUEX5/photo3_zps41f6be0d.jpg~original

Carbs and airbox installed, cables attached and initial adjustments done -

https://i5.photobucket.com/albums/y164/BLUEX5/photo4_zps469e989c.jpg~original

Had a few wiring based issues, most frustrating one being down to the pattern ignition switch having two brown wires instead of one brown and one grey. Lead to an issue with hi and low beam being the wrong way round and the clock lights not working until I figured out one of the wires should go to grey. Evil or Very Mad

Also had issues with non functioning electric start (I used the solenoid that didn't look like it was off the titanic, turns out the rusty one actually works Confused

) and brake light not working due to duff light unit, lucky I have a spare, just needs paint. Hopefully shocks of the correct length will arrive this week so I can fit the exhausts then maybe think about seeing if it goes....
____________________
18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

almostthere · Traffic Copper Joined: 28 Oct 2013 Karma :

pics of the gsxr 1100 please!
____________________
Beer, It's the reason I get up every afternoon
www.mfairco.uk

lihp · World Chat Champion Joined: 22 Sep 2010 Karma :

Very nice, although I see dirt. I hope that is genuine Suzuki dirt on this!
____________________
covent.gardens: lihp is my most favourite member ever

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Well, another decent day. Shocks of the correct length arrived so I could get on with fitting the chain and exhaust system. Also received an air filter element, which meant there was only one thing left to do, run the bloody thing!!!!

https://i5.photobucket.com/albums/y164/BLUEX5/th_DanielPeacock_zps60612838.jpg

It runs well, doesn't appear to be any issues other than leaky carbs. I've had them off and checked floatbowl screws and float height, they are back on now, but there is still a very slight leak from the float bowl to body joint on the choke side. Probably buy some new float bowl gaskets in case I have to go in there again. No nasty oil leaks or signs of duff crank seals, and the automatic oiling appears to be working.
____________________
18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

trevor saxe-coburg-gotha · World Chat Champion Joined: 22 Nov 2012 Karma :

Ooh! Big moment. Sounding gooooooood. Be nice to see it down squires of a thursday soon.
____________________
"Life is a sexually transmitted disease and the mortality rate is one hundred percent."

Mobylette Type 50 ---> Raleigh Grifter ---> Neval Minsk 125

Shreeve · Scooby Slapper Joined: 01 Jul 2013 Karma :

How do you get to a point where you're confident/capable of doing all this work?

It just seems like an insane learning curve as a new rider with an interest in this side of things.

Looks amazing so far!
____________________
Current: Suzuki GSX650F (2010), Suzuki GSXR1000 K7, Suzuki GS250T (1980) currently restoring: Clicky.
Previous: Honda CBF 125 (2011), Suzuki GSXR750 K4

N cee thirty · Banned Joined: 31 Jan 2010 Karma :

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

bypass2 · Spanner Monkey Joined: 12 Sep 2013 Karma :

Sounds good. done a good job there. Slight leek with the carbs had that on my x5 tried everthing the only way it stoped was start the bike up then turn the petrol on about 2 seconds later. Then when finnished turn the petrol off first leave it running then turn the ignition off cured it. Are the float valves jets seated right or sticking.