TS 250 Long Term Restoration

[killerbanjo]

Posted this in general at first trying to find out what version it was but have now decided to make a thread about it. Bought it for £100 with two engines, one that he thought was seized but i had a piece of tool handle in it lol, its fine. Yet to really look at the motors but both rotate freely.

As I got it:
https://i.imgur.com/RZ78ZHy.jpg

https://i.imgur.com/vlpvoJU.jpg


Stripped and started to grind the crap off the frame:
https://i.imgur.com/UvVDb46.jpg

https://i.imgur.com/dujOOkt.jpg


Cleaning shocks:
https://i.imgur.com/mFBxECm.jpg

https://i.imgur.com/ihh0k11.jpg

https://i.imgur.com/lpcsM4c.jpg


Carb Clean, seems to be a hard white buildup like calcium or limescale. Anyone know what it is?

https://i.imgur.com/1srdiPV.jpg

https://i.imgur.com/DjZpETf.jpg


Thats it for now folks. If you kno what version it is please tell. It has an ER headlight but an older thank and rear mudguard!?

[Alice-In-Sunderland]

Will be a nice project if you van find parts for it. The white "limescale" in the carb is aluminium oxide.

[killerbanjo]

I did wonder if it was zinc or aluminium oxide after lots of thinking I ended up cleaning the jets and all the passages well but leaving the real tough to get parts on there. if its that tough then it yang going anywhere...

As for parts I'm not bothered about original bits. As long as it looks the parts. I'm thinking along the lines of a daytime MOT at the moment and a 2 stroke 250 is pretty thirsty and it will be my green laner. I do plan on riding it unlike many restoration projects haha

[blurredman]

Pretty saught after bike when original, the 250's.

I always wondered how well they could cope offroad.
____________________
CBT: 12/06/10, Theory: 22/09/10, Module 1: 09/11/10, Module 2: 19/01/11
Past: 1991 Honda CG125BR-J, 1992 (1980) Honda XL125S, 1996 Kawasaki GPZ500S, 1979 MZ TS150.
Current: 1973 MZ ES250/2 - 18k, 1979 Suzuki TS185ER - 10k, 1981 Honda CX500B - 91k, 1987 MZ ETZ250 (295cc) - 39k, 1989 MZ ETZ251 - 50k.

[garth]

Pegs are a little low offroad compared to modern stuff. Engine is good though, very tractable and will always start when you stack it!

Good luck finding an exhaust.

[killerbanjo]

My dad said that his TS 250 was his favourite bike of the countless bike he had (worked for the Suzuki importers). I have an exhaust just no end can, I had taken it off before I though I should get a photo of it as I got it.

[pepperami]

I had two TS 250`s in the past.
Both were as good as gold.

I was never able to kill that engine , and I`m a heavy handed clut`z.
Very easy to ride, and the engine was quite tractable
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I am the sum total of my own existence, what went before makes me who I am now!

[killerbanjo]

Shocks are finally done
https://i.imgur.com/iasVAtM.jpg

No real progress as I need to find a new place to put it!

[pepperami]

still watching !
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I am the sum total of my own existence, what went before makes me who I am now!

[killerbanjo]

[mrb-solutions]

Keep it coming, Love watching projects like this! Good luck!

[MattWadz]

looks awesome!
____________________
Pitbike x2, Mini Moto x4, China Quad, 02' Suzuki AP50 > 03' MBK Nitro > 86' Suzuki GP100 > 02' Yamaha Jog R > 57' Honda Lead 100 > 95' Piaggio ZIP Rst 50 > 51' Suzuki TS50x > 83' Honda CB125TDE Twin > 51' Yamaha Aerox > 98' Kawasaki KX60 > 89' Yamaha DT50MX > 80's Honda QR50 > 05' CG clone > 125cc China Pitbike > 91' Honda MTX125 RW-L > 09' Peugeot Speedfight 2 LC LR > Lucky MX 140cc > Apache Tomahawk 50 Quad (current = 2010 Yamaha WR125R

[killerbanjo]

Ok so it looks like the farm building does not have enough room So right now ive cleared my wardrobe out and I think almost everything but the frame will fit in there! I put some DT 125 forks in there and a 21 inch tyre for scale. its 42cm deep, 82 long and 100 cm high. What do you guys reckon? Then all I would have to do is find space for a the frame?

https://i.imgur.com/qvSRt5N.jpg

My dad says that he DOES NOT WANT BIKE BITS ALL OVER MY MY ROOM lol, but if there tidy away he wont even see them so cool right? Ill make sure I move all the bits when I know he is out for the day...

Also a question. How to I get a seized swing arm bolt out? Last time i had a look at it I managed to get it rotating freely but it wont budge even when I hammer it. I really do not want to damage the thread though so next time ill get some brass and use a sledgehammer or something...

[pepperami]

Find a nut that matches the thread on the swinging arm bolt.
Remove the original nut and replace with the new one and tighten up .
Now back that nut off 1or2 turns.
carefully hit that nut square on with a heavy lump hammer (do not use all your strength).
if the bolt has moved a bit , on the other side the bolt will be sticking out a tiny bit.
Squirt the gap with some freeing oil and knock the bolt back in.
now squirt the gap between the nut and the swinging arm and knock with lump hammer.
Keep repeating this process , increasing the lengths until the bolt can be removed.

I hope this makes sense to you ?
____________________
I am the sum total of my own existence, what went before makes me who I am now!

[stickybackbob]

The swingarm bolts in these are a real pain in the arse. Rode my ER for 3 years before laying it up for 12 years. Getting that bolt out nearly ended up scrapping it during the rebuild! There are two metal bushes inside the swing arm. They rust onto the bolt holding it in the arm. I would say that if you haven't ruined the thread and don't feel any movement in the bearings, then leave it for now and just try and get some lubrication in there. May be worthwhile trying to get a grease nipple into the arm.

If you must get the bolt out, I tried hammering it (with the nut on) with various hammers. Next I tried to get a bit of heat in there before hammering but still no progress. Some people have managed to get them out by putting the frame into a press but I didn't have that option (need a fair few tonnes of pressure if I remember). What I could do was to get a thin blade between the frame and arm and cut the bolt! I went this way as I had a spare swing arm with pivot bolt and new bushes.

I added a grease nipple to the middle of the arm so that I can get grease in there and hopefully stop the spacers from seizing up again.

Just as an added point, once I got the chopped up bolt out, I tried to get the spacers off. Even when I had them glowing cherry red from heat, they would still only just move!

[suzukirider19...]

nice work reminds me of the ts250er i had i only have restored mine before i sold it.
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husky sm610

[69chris]

had the same problem trying to get the spindle out of my crm250 (they suffer too !!)

i used these items......

https://i157.photobucket.com/albums/t78/71bugslug/007.jpg

needed a suitable drift to avoid buggering up the spindle,
had nowt so i used a quids worth of 2p pieces taped together, thus i could whack away without fear of damage to the threads, i did sacrifice about 10p's worth of coins though

https://i157.photobucket.com/albums/t78/71bugslug/008.jpg

it worked for me, give it a try

[killerbanjo]

Haha thats a great DIY drift idea! A guy localy has just advertised a single garage for 60 a month so if I can get that then the project will start rolling again

[ShepShep]

howd you take the shocks apart? I wanted to do it but didnt fancy getting my head taken off by that spring.

[killerbanjo]

Used a set of gas plyers and put each handle inbetween the coils on either side. That allowed me to rest it against some wood on the floor and press down really hard and I got my friend to grab that split retainter you see in the pics. Once thats off the spring can be unloaded and it just comes right off. It not under that much compression so don't be scared! It's no problem but would be very difficult if you did not have a second pair of hands.