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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
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PostPosted: 12:30 - 10 Jan 2015    Post subject: 1980 Suzuki GS250t Restoration - Very Picture Heavy! Reply with quote

Suzuki GS250t, delivered yesterday. Runs but has a few things that need fixed:

http://www.bikechatforums.com/viewtopic.php?t=298734

It's in need of some love and tlc so should be a nice bike to tinker on.

Going to give it a good clean, already ordered a new gear shift seal as this is where the oil is leaking from (only a tiny bit but the seal was 3 so why not change it).

Also ordered a new clutch lever assembly which was 7, cheap as chips!

http://i62.tinypic.com/2da0nps.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


Last edited by Shreeve on 19:16 - 23 May 2015; edited 4 times in total
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pepperami
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PostPosted: 13:52 - 11 Jan 2015    Post subject: Reply with quote

Keep us updated Thumbs Up
Interested on how this bike fairs, as I thought it would make a good little tourer?
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Shreeve
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PostPosted: 18:05 - 12 Jan 2015    Post subject: Reply with quote

Had my first chance to give the bike some love today. First job was to clean the bottom of the engine as it was absolutely caked, felt like I went through half a litre of WD40!

Ready to get stuck in...

http://i58.tinypic.com/in4ugy.jpg


After filling a large bag with rags and oil soaked everything (no pics as couldn't hold my phone) I changed the cardboard and cleaned up a bit.

Next task was to take the front sprocket cover off as something was sticking when changing gear and putting it in neutral was next to impossible, I was hoping it was just some caked on dirt and not something more sinister.

http://i61.tinypic.com/jre6oy.jpg

As i'm just a young'n I'm still building up a decent set of tools, buy when I need, this really annoyed me though...

http://i62.tinypic.com/2h8aedu.jpg


After a trip to B&Q (check out the DIY gear shifter rubber!!)...

http://i60.tinypic.com/o8hpoj.jpg


Cover off, lots of lovely oily goodness to clean up! Sprocket looks fine.

http://i57.tinypic.com/28ulawm.jpg
http://i58.tinypic.com/eg4hfb.jpg


More loveliness...

http://i61.tinypic.com/2rxa15x.jpg


Took the seat off to have a look which turned in to a nightmare as the Top Box rack jammed the whole thing down, lots of frustration later...

Looks like the seat hasn't been off in a long time.

http://i59.tinypic.com/30hsxhj.jpg
http://i60.tinypic.com/taocie.jpg

Seat back on, cleaned and lubed the chain and took it out for a ride. Absolutely no complaints now. Gear changes are smooth, above 6k revs it pulls well and it's more than happy to go in neutral!

http://i58.tinypic.com/smg5ua.jpg


Little bit of choke on ignition, let it sit and warm up till the engine note changes and it's happy to do whatever you want!! In a way i'm a bit disappointed it's working so well as I was looking forward to taking it apart and looking at all the gubbins. Now it's more of a 'it's not broken so don't fix it' scenario.

I also bought an old copy of Classic Motorcycle Mechanics from Apr '81 which has a 2 page spread about the bike:

http://i61.tinypic.com/14c9oqv.jpg
http://i62.tinypic.com/sopls5.jpg

Just going to ride it until something breaks and fix things as and when, can't wait for a few trips to Hartside and Wetherby, bring on the sun! Smile
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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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Shreeve
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PostPosted: 22:03 - 19 Jan 2015    Post subject: Reply with quote

Well I fancied getting a few more niggles sorted out this weekend, first was the fact that on the indicator the piece of plastic you push to move it has broken off so I bought a new LHS on eBay.

The new one was very old so I solicited the help of my father who is a veteran electrician of 40+ years to help test and install it, what could go wrong I thought...

Setting up his 'testing rig'

http://i58.tinypic.com/2q8vw9z.jpg
http://i58.tinypic.com/wvobyg.jpg


'New' one on the right, you can see what I mean about the old indicator having the snapped piece of plastic. Problem is the one from eBay is from the US model and the one that was on the bike is actually (after much research to find out) from a GN125.

http://i57.tinypic.com/52tqx.jpg


'Testing rig' set up...

http://i62.tinypic.com/2ajrsja.jpg


Tested the new one to find the horn and Hi/Low switch didn't work so opened it up to have a look.

http://i58.tinypic.com/1zl624m.jpg


Realised a soldered connection on the horn had cracked. Setting up the soldering iron that hasn't been switched on in probably 10+ years.

http://i59.tinypic.com/xcjbcm.jpg


This took, literally, an hour. This horrible bloody fiddly sodding horn assembly can die in a fire...

http://i60.tinypic.com/2z4k0sk.jpg


While testing our handy work, the veteran electricians 'testing rig' shorted the whole bike blowing the main fuse Sad

http://i57.tinypic.com/mvkvbn.jpg


After this we put the old LHS back on and decided it was time for a brew - wish I was as content as this big fella...

http://i57.tinypic.com/dpdzc5.jpg


Next day I decided to tackle a couple more things, firstly to B&Q to get some cleaning supplies (that peek polish is pretty good!).

http://i62.tinypic.com/2r5g5n8.jpg


The thought of cleaning a 34 year old oxidised engine terrifies me so I thought I would take off the top box rack instead. I've bought a standard chrome grab rail from eBay as I want to make it as standard as possible.

Indicators off.

http://i62.tinypic.com/smwqp5.jpg


It's a really weird rack, doesn't seem to fit very well.

http://i59.tinypic.com/2wgeoib.jpg
http://i61.tinypic.com/34hymfc.jpg


Looking better!

http://i58.tinypic.com/2eyfbj9.jpg
http://i58.tinypic.com/2qbupkw.jpg


Indicators back on, not happy about the brackets holding them but i'll worry about that later.

http://i61.tinypic.com/vxg6t4.jpg


Used heat shrink and a heat gun for the first time!

http://i58.tinypic.com/2lvb5p1.jpg


And finally I took off the foam grips and put on some cheap super grips, that's it until next weekend!

http://i57.tinypic.com/1ze9jio.jpg


I need to start cleaning the engine. On that note, if anyone has some tips on how to clean an engine without taking it out of the frame I'm all ears. So far i'm going with the method of:

WD40 + scotch brite all over.
Degrease + dry.
Bremel + wire brush adapter all over (might take a few years)
Peeks polish as much as possible.

This is most likely not the most pragmatic way to do it so please help with some nuggets of wisdom if you can Smile
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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: 19:55 - 22 Jan 2015    Post subject: Reply with quote

Didn`t you say it had an oil leak?..... what new that?
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Shreeve
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PostPosted: 20:31 - 22 Jan 2015    Post subject: Reply with quote

I've got the gear shifter seal but waiting on a final drive seal, need to drain the oil so best to do them at the same time.

To be fair calling it a leak is probably an exaggeration, once it's been for a run 2-3 drops can be seen next to the centre stand. I've checked the oil loads and it doesn't seem to be going down at all.
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Shreeve
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PostPosted: 18:44 - 25 Jan 2015    Post subject: Reply with quote

Decided to tackle the front brakes today.

This is what i'm working with...

http://i60.tinypic.com/2uqkcyb.jpg


Bought a cheapy bleeding kit from Halfords and set about the bleed nipple. Cheap spanner = started to round off Sad

http://i62.tinypic.com/2n0966h.jpg


Proper socket = success!!

http://i57.tinypic.com/259vayh.jpg


Even just changing the fluid made a huge difference but I want to be sure so took the caliper off and checked out the pads. Realised I failed miserably and took off the whole assembly...

http://i59.tinypic.com/301gcx3.jpg
http://i59.tinypic.com/246nevo.jpg


Put it back on and took the proper part off...

http://i62.tinypic.com/1115wcp.jpg


Maybe best off getting new pads.

http://i59.tinypic.com/2iqmjxd.jpg


As far as the piston goes...

http://i62.tinypic.com/bi0409.jpghttp://i57.tinypic.com/nlcv2o.jpg


While I wait for new pads to come I have questions:

1) What's the process for completely bleeding it to remove the piston?

2) Any good guides on cleaning calipers?

3) How will i know which seals I need to buy?

Apologies for the naivety and appreciate any help if i've missed something obvious out.
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Shreeve
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PostPosted: 19:18 - 25 Jan 2015    Post subject: Reply with quote

Google shall provide:

https://www.youtube.com/watch?v=aeb-tN_nKYA

That's next on the list then!

Order Contents:
1 x Bleed Nipple - Front - Stainless Steel
1 x Pads Front Kyoto Standard (GG Type)
1 x Piston Seal and Dust Seal Front Brake

After i've cleaned the piston i'll see if it's salvageable, most likely not Sad
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Irezumi aka Reuben
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PostPosted: 19:41 - 25 Jan 2015    Post subject: Reply with quote

If your stripping and re-doing the brakes get some red rubber grease. Any auto parts place (even Halfords I'd imagine) will have it. Put this all over the piston/inside the caliper and around seals etc.

For the engine get some Jizer. Spray this on all the really greasy parts/all over the engine/bike then leave for 15-ish minutes. Get a hose (doesnt need a jet wash) then watch the grime come off (well most of it).
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Shreeve
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PostPosted: 21:25 - 25 Jan 2015    Post subject: Reply with quote

Is there a reason red grease is better than rubbing it all in brake fluid?


After watching that video I felt inspired so since posting that last post, this has happened - Piston and rust infused brake fluid out.

http://i60.tinypic.com/24negbc.jpg


Lovely.

http://i58.tinypic.com/2q1t6pd.jpg


Ordered a new Banjo bolt as they're cheap and this one was a bit nasty.

http://i58.tinypic.com/352ql43.jpg


Gooshed.

http://i61.tinypic.com/xlksww.jpg


Weird seal.

http://i57.tinypic.com/2q0orck.jpg
http://i57.tinypic.com/15nxb2w.jpg

http://i58.tinypic.com/ji0wwi.jpg


No idea what this is called.

http://i59.tinypic.com/eqnvrp.jpg


Scrub-a-dub-dub.

http://i62.tinypic.com/qs39jt.jpg
http://i61.tinypic.com/254wqyp.jpg


And done...

http://i59.tinypic.com/j67go3.jpg


So, the piston looks a bit buggered so i've ordered a new one to be on the safe side.

http://i58.tinypic.com/a72ix.jpg
http://i57.tinypic.com/108fsxf.jpg
http://i61.tinypic.com/25fj2hi.jpg
http://i60.tinypic.com/ehaur9.jpg



Now just waiting for parts and i can put it all back together, 4 hours ago I didn't even know how to bleed brakes now i feel like an expert!
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Irezumi aka Reuben
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PostPosted: 22:10 - 25 Jan 2015    Post subject: Reply with quote

Shreeve wrote:
Is there a reason red grease is better than rubbing it all in brake fluid?

It helps prevent the seals from drying out and perishing. It will also make assembling the brakes a lot easier. It's normally supplied in small packets with re-build kits for hydraulic systems (such as brake and clutch). It's also just what you should rebuild brake calipers with!
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Fladdem
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PostPosted: 22:17 - 25 Jan 2015    Post subject: Reply with quote

Cool, the piston on my GPZ was worse than that, I wish I'd ordered new bleed nipples as well, I still reused the piston, in hindsight, I would change it. But I can't be bothered to tear into the caliper again.

http://www.bikechatforums.com/viewtopic.php?t=284267 (First post shows my piston, if you're interested)

It's looking good so far though. I only briefly skim-read it, what's the plan tart it up a bit or just get it working perfectly but looking a bit scruffy still?
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Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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Shreeve
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PostPosted: 22:30 - 25 Jan 2015    Post subject: Reply with quote

Thanks Reuben - appreciate it.

Fladdem - i've been watching your thread with interest, looks like you've got your work cut out!

My plan is to make sure it is functionally working then tackle the cosmetics. I'm going to the TT for practice week and undecided whether to take this or my GSX650F.

Whoever had it before me painted the tank with a brush Rolling Eyes
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Fladdem
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PostPosted: 22:38 - 25 Jan 2015    Post subject: Reply with quote

From now on, if I ever have any doubt at all about brakes, I'll replace all the consumables, pistons, seals, nipples, banjo bolts, saves a lot of hassle.

I replaced the rear master cylinder on my CRM the other day at work. I went to bleed it and snapped the sodding bleed nipple off flush to the caliper, I went to drill the thing out to fit a 10mm nipple from stores, standard is 8mm, and snapped the drill bit off in the caliper.

I then left it as is, and I had to bleed the brakes through the banjo bolt, I took the caliper off, turned it upside down and used a pair of mole grips to hold the piston in. I got fluid everywhere, but luckily work has an inexhaustible supply of rags and brake cleaner. Laughing

Sounds like a similar plan to me, I want to get it stopping as well as can be expected, then I want all the bearings to not be naff, then I'm going to sort out the suspension, followed by fresh rubber, then I'll try to get her running nicely, cleaning carbs, setting valve clearances, stuff like that. Then, possibly clean the engine really well, and try to paint it with some VHT, or if it will make it worse, come up with another solution. I won't respray it, I think mine would come up looking good with just a few hours polishing. Thumbs Up

I bet the tank would have looked better as it was before someone attacked it with a brush. Thumbs Down
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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!)
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.Chris.
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PostPosted: 22:55 - 25 Jan 2015    Post subject: Reply with quote

That caliper looks more or less identical to the one on the GN400. When I first put the bike on the road mine was in a slightly worse state than yours, judging by the looks of it, and the front brake was poor, although plenty good enough for an MOT. Once rebuilt and with a new set of pads the difference was like night and day.

I've often been tempted to get a GS250T. For your sake I hope the electrical system is better than the one on the contemporary GN, which is the main reason I'm looking to get rid of it.

Hope the bike brings you good times Thumbs Up
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Shreeve
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PostPosted: 21:47 - 26 Jan 2015    Post subject: Reply with quote

Cheers Chris Smile

Well I got a nice package from the USA today, 34 year old grab rail! Looks much better than the horrendous top box rack:

http://i62.tinypic.com/33vyzaq.jpg


Started cleaning the caliper a bit more, consisting only of sanding, sanding, sanding.... sanding..........

http://i60.tinypic.com/4rdqx3.jpg
http://i58.tinypic.com/2d0zbdw.jpg
http://i59.tinypic.com/wujyop.jpg

Ordered some VHT heat resistant black paint so hoping this turns out good as new!
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Shreeve
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PostPosted: 18:30 - 27 Jan 2015    Post subject: Reply with quote

So my left hand indicator works fine, if I turn it right the relay buzzes like mad, is it as simple as get a new relay?

Edit: Nevermind, both front indicators were wired by a half blind one armed child and have earth faults. Was going to buy new ones anyway!

I hate auto electrics Sad
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Shreeve
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PostPosted: 20:58 - 27 Jan 2015    Post subject: Reply with quote

I realise I'm pretty much talking to myself in this thread, only way I get any sense Wink


New parts!!

http://i62.tinypic.com/14ij2uw.jpg
http://i60.tinypic.com/14j4tx5.jpg
http://i62.tinypic.com/29nxrt2.jpg


The bike came with no front brake switch at all, it came today. After a horrendous amount of effort and through using some power cable wires (and electrical magic) the front brake switch works but both front indicators have earth shorts. Ordered new standard indicators anyway as I want the bike to look like it did in the 80's so left it as is for now.

http://i59.tinypic.com/6pvytj.jpg
http://i58.tinypic.com/y1ok3.jpg
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DrDonnyBrago
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PostPosted: 09:18 - 28 Jan 2015    Post subject: Reply with quote

Kudos to Suzuki having the brake piston gaiters to keep shit out of the brakes!

Cars have them, and brake seals last 150,000 miles + as a result, the seals and pistons on my ancient, overused and neglected first car looked as good as new.

Looking like a good project, nice to see an old bike getting some love (and a brake refurb).
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Shreeve
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PostPosted: 09:49 - 28 Jan 2015    Post subject: Reply with quote

I did wonder what that was called, it seems to have done the job!
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ride_to_die
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PostPosted: 11:50 - 28 Jan 2015    Post subject: Reply with quote

Top work mate Thumbs Up

Seems like your progressing well.
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UncleBFester
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PostPosted: 12:52 - 28 Jan 2015    Post subject: Reply with quote

That part you have that sits between the caliper and the rear of the pads is to stop them rattling when there is no pressure on the brakes.
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buaan
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PostPosted: 14:54 - 28 Jan 2015    Post subject: Reply with quote

Keep it up, really interesting read. Good progress. Seat looks comfy, a lot more than the arse buster on my DRZ. Laughing

Whats the plan for the bike? Commuter and wet/salty weather transport?
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Shreeve
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PostPosted: 15:27 - 28 Jan 2015    Post subject: Reply with quote

I initially bought it so I could learn more about bikes and I had some cash lying around after selling my gixxer - there wasn't really a plan as such. I've got my GSX650F as the workhorse so this thing will most likely turn into a little tourer or weekend toy (despite it being rather slow of course!). Guess I'll just see how it goes.

Was looking to buy a new front brake hose as the one on the bike is way too long but it has a weird adapter to the master cylinder so I've decided to save some money and just cable tie it to neaten up the route to the caliper. Not too happy about the ugly outer protective hosing though.

http://i62.tinypic.com/f4429v.jpg


Caliper paint should be here soon so off with the support bracket to remove some of the gunk. In the first picture here, what's the metal bracket i'm holding, it was attached to the nearest bolt opening and didn't seem to be serving any purpose?

http://i58.tinypic.com/2rem9w9.jpg
http://i57.tinypic.com/708dhd.jpg
http://i60.tinypic.com/21jajc0.jpg
http://i62.tinypic.com/zn39rn.jpg


Love a bit of lube.

http://i57.tinypic.com/33bmsdv.jpg


Cleaned the disc and put the bracket back on. Looks much better! (wheels are on the to do list).

http://i59.tinypic.com/2im2reh.jpg
http://i60.tinypic.com/2m7yw4o.jpg


Prepped the caliper for my horrendous attempt at a rattle can paint job. I want the bolt heads painted black too so this is my attempt at ingenuity. I'm a Geordie so it's the best I can do.

http://i61.tinypic.com/2la99x5.jpg
http://i62.tinypic.com/2rm4ods.jpg


Now to the questions:

Whoever had this before me glued one of the Suzuki badges to the tank and it's bubbled all the paint. I don't want to spend a fortune on this project so would rather avoid getting the tank stripped back and repainted. With that said I'm not sure what my options are and would love some input.

http://i58.tinypic.com/160vc7d.jpg


Haynes Manual says these shocks can't be taken apart and if they lose any oil or leak they need replaced. It also says not to get any lubricant on the main rod in the middle. What's the best way to go about cleaning them?

http://i59.tinypic.com/1zpns4p.jpg


Saw this, had to buy it Embarassed

http://www.ebay.co.uk/itm/291299553453
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pepperami
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PostPosted: 21:03 - 28 Jan 2015    Post subject: Reply with quote

The paint bubbles is a difficult if you are not stripping back? , how about a pin prick into the bubbles and flatten them?

As for the bit of metal you are holding? is that not a holder that the cable/pipe used to pass through, but it`s been bent open at sometime in the past? possibly?

Sorry to say this, but those rear shocks look bent? or is it just my eyes?


You are doing a great job on this bike Thumbs Up
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The last post was made 3 years, 353 days ago. Instead of replying here, would creating a new thread be more useful?
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