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1980 Suzuki GS250t Restoration - Very Picture Heavy!

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 Topic moved: from General Bike Pictures to Show & Tell by G (27 Jan 2015 - 18:18)
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Shreeve
Scooby Slapper



Joined: 01 Jul 2013
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PostPosted: 19:14 - 23 May 2015    Post subject: Reply with quote

Well I'm not one for sitting around so thought I would put some graft in.

Please note: I have no mechanical knowledge (bar what this bike has taught me).

Seat off.

https://i57.tinypic.com/161b1au.jpg


Indicators off.

https://i58.tinypic.com/24l3ok5.jpg


Tank off.

https://i62.tinypic.com/2dgnz90.jpg
https://i59.tinypic.com/2s6otvn.jpg


This picture really brought home how much of a task this will be Shocked

https://i61.tinypic.com/2db5mpl.jpg


Decided to drain the tank next, it didn't feel too heavy so I thought I could do it in a couple of 2L bottles... As you can see there is a black Jerry Can behind which I had to buy from B&Q and yes i put all of the petrol in it. The smell of petrol, genuinely love it, might have got a bit light headed doing this Mr. Green

https://i59.tinypic.com/28ahiz9.jpg


Petcock off - bit bent at the top but still working fine. Vacuum still works, no leakage when set to On.

https://i58.tinypic.com/33bz9sw.jpg


Various other parts removed.

https://i62.tinypic.com/105z6fr.jpg


The electrics actually scare me... easy pulling them apart but how the f*** am I going to put them back?!

https://i62.tinypic.com/14mxlle.jpg
https://i58.tinypic.com/uo6et.jpg


Sidestand gunge Sick

https://i59.tinypic.com/111qryw.jpg


Chain off, sprocket is still in good working order. Slightly oxidised but that will clean up nicely. Chain was absolutely cream crackered, seized links galore.

https://i58.tinypic.com/167rz3l.jpg
https://i60.tinypic.com/r2p282.jpg


Headers and exhaust off. I think the previous owner bought the exhaust, it's a Motad and is in decent condition bar some light pitting. You can also see the pan full of WD40 i'm using to soak bolts / nuts etc.

https://i62.tinypic.com/dyoro7.jpg
https://i62.tinypic.com/14nd9au.jpg


Thought it best to tackle the rear wheel next, axle nut off and rear drum brake fixings off.

https://i57.tinypic.com/xgdtaf.jpg


It kinda fell apart when I took it off. The rubbers seem decent, how often to do you have to change them? HOW THE HELL DO YOU TAKE THOSE SPRINGS OUT OF THE REAR DRUM???? Evil or Very Mad

https://i59.tinypic.com/fjjjo9.jpg


Looks weird...

https://i59.tinypic.com/2vuwimw.jpg



Shocks, rear fender and extender off.

https://i61.tinypic.com/ofuc2b.jpg


This is how i'm going to tackle the scary electrics...

https://i59.tinypic.com/2q9z2np.jpg


Battery is in a really stupid place + so many wires Sad

https://i61.tinypic.com/27zagp5.jpg


Various electrical items removed. No idea what the first item does but I know the second is the indicator relay?

https://i61.tinypic.com/1zr29zp.jpg
https://i57.tinypic.com/2zsbomw.jpg


Right, I know nothing about electrics and I put a spanner around the bolt connected to the big red lead. Much pain ensued Sad don't like electric shocks...

https://i57.tinypic.com/314zae0.jpg


What's this for? I know the airbox provides air to the carbs for the air/fuel mixture so am I right in thinking this hose provides the air for the first engine stroke (suck)?

https://i61.tinypic.com/w02qe0.jpg


Disconnected the airbox from the carbs, removed the battery holder and tried to remove the airbox. Tried... no matter how I moved it the bloody thing won't come out. Am I right to assume the only way to take it out is through the front meaning removing the carbs and engine? Surely not...

https://i57.tinypic.com/2w5vrf6.jpg


This is how I left it today as I'm knackered. Been a fun day though - dreading putting it all back together and the cleaning is going to take a lifetime Laughing

https://i59.tinypic.com/15i9abr.jpg
____________________
Current: Suzuki GSX650F (2010), Suzuki GSXR1000 K7, Suzuki GS250T (1980) currently restoring: Clicky.
Previous: Honda CBF 125 (2011), Suzuki GSXR750 K4
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Just_James
Could Be A Chat Bot



Joined: 29 Aug 2014
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PostPosted: 19:29 - 23 May 2015    Post subject: Reply with quote

Nice work Very Happy Thumbs Up

It can be daunting stripping a bike but you're going about it the right way, label up anything you're not sure of and take LOTS of pics especially of electrics etc, they cost nothing and can be a life safer when it comes to rebuild.
I also tend to buy a couple of packs of food bags with zip fasteners then any small bits and pieces are put in those, grouped together where necessary and labelled. Keeping everything organised keeps the rebuilding part mostly stress free Wink

Keep up the good work and enjoy it!
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Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125
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Fladdem
World Chat Champion



Joined: 29 Jun 2011
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PostPosted: 19:39 - 23 May 2015    Post subject: Reply with quote

Cool! I'm not well organised enough, nor do I have the space to start stripping a bike completely down to nothing. I'm helping build a shed with Dad so I can have that with my MT5 and stuff related to it inside and use that for when I strip it down.

With regards to the cush rubbers, if there is slop in-between the sprocket carrier and the hub, you can pack the paddles out with bicycle inner tubes. If you look in my GPZ project thread, I have a post about how I did it.

I don't want to jinx it, but have you had many rounded nuts and bolts yet, what about stripped threads? Loads of bolts on my TTR, I would undo and the thread would just come out with the bolt, wrapped round it, loads of bolts snapped on the way out as well. I've replaced loads of bolts on that bike, my tap and dies set has paid for itself, I went and bought loads of different sizes of bolts, a few drill bits and some new hack saw blades for cutting bolts down to size. Laughing
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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.
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Shreeve
Scooby Slapper



Joined: 01 Jul 2013
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PostPosted: 16:37 - 24 May 2015    Post subject: Reply with quote

Cheers James Smile

I don't have much space either but I have no choice as I'm moving house soon and taking it apart to move it in boxes seemed easier than finding a specialised transport. I think you jinxed it Fladdem, hit my first one today! No stripped threads yet thankfully. For a 35 year old bike i think i've been insanely lucky, saying that though I haven't tried to open the engine yet...


Day 2 begins with removing the Carbs.

https://i57.tinypic.com/6pw394.jpg
https://i58.tinypic.com/16kdq0z.jpg
https://i62.tinypic.com/30ur9c5.jpg


This seemed like a good idea as my garage is a dustbowl.

https://i60.tinypic.com/2s612eu.jpg


Next, continue removing the electrics - coils off and pictures to help me remember what plugs in to what and routing. You know you're out of your depth when you have to google the parts you're removing to find out what they do Embarassed

https://i59.tinypic.com/vfe4d0.jpg
https://i62.tinypic.com/15rnz1s.jpg
https://i60.tinypic.com/2mh7m7l.jpg
https://i61.tinypic.com/2u6dw9l.jpg


Disconnect the neutral switch. First time i've hit a screw/bolt that didn't want to budge - Impact Driver to the rescue! Front Sprocket looks good but they're cheap so I bought a new one anyway.

https://i61.tinypic.com/zc18p.jpg
https://i60.tinypic.com/34zip9g.jpg


Headlight and switches next.

https://i61.tinypic.com/mkejaa.jpg
https://i60.tinypic.com/2qw1rad.jpg


Labelling which wire does which indicator.

https://i59.tinypic.com/6ekw8g.jpg


After much toil, back ache and stress. The loom is off!! The routing is horrendous and i will most likely want to end my life when it comes to putting this back on. I've left some items attached like the headlight, rear brake switch and neutral switch as they will be good signposts. This needs lots of work though, going to change as many of the old bullet connectors with new ones as possible.

https://i59.tinypic.com/2mpeezq.jpg


Front brake off (too lazy to bleed it and I very recently refurbed it anyway). One annoying this here is that the M/C has a straight through connector to the brake hose but it should be a shoulder mount. I can't find any on eBay and it forces the hose to go over the speedo which gets annoying...

https://i58.tinypic.com/vdfvhz.jpg


Front wheel time. Lots of cleaning to be done.

https://i59.tinypic.com/24pf9th.jpg
https://i58.tinypic.com/wgq35s.jpg


And this is how i'm leaving it for today. I'm cream crackered...

https://i60.tinypic.com/syoyf6.jpg
____________________
Current: Suzuki GSX650F (2010), Suzuki GSXR1000 K7, Suzuki GS250T (1980) currently restoring: Clicky.
Previous: Honda CBF 125 (2011), Suzuki GSXR750 K4
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Shreeve
Scooby Slapper



Joined: 01 Jul 2013
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PostPosted: 22:03 - 26 May 2015    Post subject: Reply with quote

Tonight was the final stretch as far as stripping it down goes!

Firstly, horn off.

https://i58.tinypic.com/2s8ohh5.jpg


Tachometer disconnected from engine.

https://i57.tinypic.com/23kdp1x.jpg


Clocks off.

https://i61.tinypic.com/2itft5c.jpg


Ignition switch off.

https://i60.tinypic.com/25aq3o5.jpg


Front mudguard and bracket off.

https://i57.tinypic.com/2rpa6bc.jpg


Now, the engine... starting with the front mounting plates.

https://i58.tinypic.com/1773aw.jpg
https://i58.tinypic.com/29wvozb.jpg


Had to improvise a little with support!

https://i60.tinypic.com/2lsyyr6.jpg


This really didn't want to come out, the engine supports need some major tlc.

https://i62.tinypic.com/2mms7me.jpg


Forgot about the rear brake pedal...

https://i60.tinypic.com/2epn81g.jpg


Lower rear bolt out - again in need of some love.

https://i61.tinypic.com/116i5xe.jpg


Finally on to the main one. Ended up having to bash it out with a hammer after soaking it in WD40.

https://i59.tinypic.com/25k6asm.jpg
https://i62.tinypic.com/33ynalk.jpg


Then, after much pain (and some help from the gf! Twisted Evil ). It was out. I planned this horrendously as the engine can only be removed from the right side which happened to be where the wall was... Also, again, the airbox can only be removed after taking the engine out. I'm sure this can't be right but it really wasn't budging.

https://i61.tinypic.com/mky6ip.jpg

Quick clean up and this is how it looks after the strip. Leaving the forks on for now.

https://i60.tinypic.com/2utiuiu.jpg


This has been great fun and I've learned loads. Now the cleaning starts.

I've asked for a quote to vapour blast the wheels, carbs, rear drum brake cover and engine. I got a quote of £140-160 for just the engine but the company were based 200 miles away (I'm in Newcastle).

Going to sand the frame right back, derust then paint it. Need to do some research on what paint is best etc.

Loads of work needs to go in to this. Might be done by next summer if I'm lucky!
____________________
Current: Suzuki GSX650F (2010), Suzuki GSXR1000 K7, Suzuki GS250T (1980) currently restoring: Clicky.
Previous: Honda CBF 125 (2011), Suzuki GSXR750 K4
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gorillaonabik...
Nearly there...



Joined: 31 Jul 2011
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PostPosted: 20:20 - 07 Jun 2015    Post subject: Reply with quote

Looks like a great project. Makes me want to get a garage somewhere...
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FZR400 (blown engine), ZXR750 (blown engine), ZX6R (accident), CBR600 which had engine issues after which I learned to change gear..., CBR900, CBR924 (stolen), CB600, CB1300 (everything blew up), BMW K1300GT (written off, hit from rear while stationary), Bandit 1250 for a couple of months, Triumph Sprint ST 1050 (nicked) and somewhere in there, I wrote off a Ducati 748 at Cadwell.
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Shaft
World Chat Champion



Joined: 27 Dec 2010
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PostPosted: 23:34 - 07 Jun 2015    Post subject: Reply with quote

Shreeve wrote:
Also, again, the airbox can only be removed after taking the engine out. I'm sure this can't be right but it really wasn't budging.

Going to sand the frame right back, derust then paint it. Need to do some research on what paint is best etc.


Yes, it can be right, ask nowhere.elysium about taking airboxes out of Suzukis Laughing

As for your frame, get it powder coated - send it to the coaters as is, they will media blast it first, then coat it, achieving a better and more durable finish than you ever will, armed only with sand paper and rattle cans.
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20 RE Interceptor, 83 Z1100A3, 83 GS650 Katana
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pikey666
Borekit Bruiser



Joined: 18 Jan 2013
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PostPosted: 08:54 - 09 Jun 2015    Post subject: Reply with quote

Both elite powder coatings in wallsend and betta blast in shiremore have done good work for me on bicycle frames that needed various threads and bearing seats masked off.
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nowhere.elysium
The Pork Lord



Joined: 02 Mar 2009
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PostPosted: 10:37 - 29 Jun 2015    Post subject: Reply with quote

Shaft wrote:
Shreeve wrote:
Also, again, the airbox can only be removed after taking the engine out. I'm sure this can't be right but it really wasn't budging.


Yes, it can be right, ask nowhere.elysium about taking airboxes out of Suzukis Laughing

Yeah, airbox design appears to have been Suzuki's kryptonite in the 80s. Well I say that - the mk1 Bandit 600 still had a godawful design and that was early/mid 90s, so there's a chance that they just haven't bothered to learn from bitter experience.

Or they simply don't care.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project
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Stuster
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PostPosted: 22:18 - 04 Dec 2015    Post subject: Reply with quote

This is a fantastic project, i envy you! mine never get finished haha... looking forward to seeing the end result!
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Yamaha TZR125 x 3 Lifan LF125 14-F x 3 Jinlun 125 x 1 Honda CBR 600 F1 Honda Varadero 125cc I am now starting my Honda VFR400 NC30 Project Smile (Still ongoing 27/02/18) Daelim Roadwin 125R
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Shaft
World Chat Champion



Joined: 27 Dec 2010
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PostPosted: 02:17 - 05 Dec 2015    Post subject: Reply with quote

Stuster wrote:
This is a fantastic project, i envy you! mine never get finished haha... looking forward to seeing the end result!


It's been the thick end of 6 months since the last update, it's looking increasingly likely that you shouldn't hold your breath.........
____________________
Things get better with age; I'm close to being magnificent........
20 RE Interceptor, 83 Z1100A3, 83 GS650 Katana
WooHoo, I'm a Man Point Millionaire! https://www.bikechatforums.com/viewtopic.php?t=234035
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Shreeve
Scooby Slapper



Joined: 01 Jul 2013
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PostPosted: 20:55 - 06 Dec 2015    Post subject: Reply with quote

Shaft wrote:
Stuster wrote:
This is a fantastic project, i envy you! mine never get finished haha... looking forward to seeing the end result!


It's been the thick end of 6 months since the last update, it's looking increasingly likely that you shouldn't hold your breath.........


Have no fear, it is still ongoing!

Unfortunately I had an off in September so I am currently focussing on fixing my GSX650F.

I've had the tank and fairings painted on this since and stripped the frame right back.

I will update soon as I'm close to getting the GSX back up and running Thumbs Up

edit: I also moved house in June which slowed this down. Excuses!

Edit2: Here's a taster:

https://i68.tinypic.com/29xcaqv.jpg
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Current: Suzuki GSX650F (2010), Suzuki GSXR1000 K7, Suzuki GS250T (1980) currently restoring: Clicky.
Previous: Honda CBF 125 (2011), Suzuki GSXR750 K4
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pepperami
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PostPosted: 22:36 - 08 Dec 2015    Post subject: Reply with quote

MOAR! NOW!!!
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Shreeve
Scooby Slapper



Joined: 01 Jul 2013
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PostPosted: 08:36 - 17 Dec 2015    Post subject: Reply with quote

Going to be on hold even longer now, binned the GSXR on the way to work and broke my collarbone!

https://i65.tinypic.com/dymw6t.jpg
https://i64.tinypic.com/90n61z.jpg

Crash bung did its job amazingly, this is the only damage, been very lucky!
https://i65.tinypic.com/2jfma2u.jpg
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Current: Suzuki GSX650F (2010), Suzuki GSXR1000 K7, Suzuki GS250T (1980) currently restoring: Clicky.
Previous: Honda CBF 125 (2011), Suzuki GSXR750 K4
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pepperami
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PostPosted: 21:08 - 17 Dec 2015    Post subject: Reply with quote

Shreeve wrote:
talked about his broken bones and other bike
https://i65.tinypic.com/2jfma2u.jpg


Tut Tut I`m sorry Mr Shreeve, this will not do, hurry up and get better so you can continue to amuse me with this thread Folded arms Wink
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lilredmachine
World Chat Champion



Joined: 24 Jan 2005
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PostPosted: 18:57 - 13 Jan 2016    Post subject: Reply with quote

Shreeve wrote:
Stunning! Where did you get the tank and fairings done?

Braided hoses are on the to buy list Thumbs Up


Sorry for the ages to reply, but the tank and panels were a lucky find as someone was breaking one on ebay and the paint was good. The only thing wrong with it was the shocks had been replaced for shorter versions at some point. These are very rare bikes now, there were never very many gsx-xxx-ts about as most plumped for the more modern designs available at the time.

Rode lovely and had big time punch from the little twin, just as quick as my gs550e in the real world.
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