1975 Suzuki GT250m
Another new project….
This time I’ve managed to get my hands on a 1975 Suzuki GT250m with RAM AIR System, twin cylinder, 2 stroke
Over the coming weeks I’ll be updating this page as i go along, including pictutres and hopefully video, with out further adieu…
Stage 1: Analysis
Aug – Sept 2010
I bought the bike at the end of Aug 2010, in the purchase I got a lot of spare parts, some that would be fix-able or usable and some that wouldn’t, When I got the bike to the shed I had a right good look over it, when I removed the head and barrels it all looked well, it had been re-sleeved and rebored at some point, and new pistons had been fitted, although one of the pistons the rings were stuck, I had the engine running before stripping it and it was quite smokey, so I opted to split the cases and check the crank seals, the outer bearing on the clutch side had collapsed!!, I managed to source a good 2nd hand bottom end and rebuilt the engine using good parts from both engines, but still retaining the original case with the all important engine number…
Stage 2: Strip Down
Aug – Sept 2010
The entire bike is currently stripped, going to get power coated, all other items have been catalogued and recorded, I’ve managed to source lots of spare parts for the bike from the likes of ebay and scrapyards,So until things get back from the Power coaters, ill leave you with the gallery below….
hope you like it, as always feel free to leave your comments…
Stage 3: Powder Coating
Update – 12/09/2010
Got my bits back from the powder coaters, I think they turned out great…
Stage 4: Zinc Plating
I bought myself a DIY zinc plating kit off ebay, it was about £70, but works a treat, as long as the part ur plating is verrry clean, ive been soaking the parts in brick acid (Hydrochloric acid) and buffing down with a wire brush on the pillar drill, some of the parts look ok.
Stage 5: Engine Stripdown
When i bought the bike the seller “John” had told me that the top end had been vapor blasted and been rebored with new pistons fitted, and true to his word, the barrels, pistons, heads were all in mint condition, the only thing needing doing was to free off the piston rings on the right hand piston, the bottom end was a different story, the big end on the conrod looked to be in great condition with very little wear as was the centre bearing, and the left had side main bearing, the right bearing had collapsed and the outer shell of the bearing had spun in the cases!! shit,,, I hunted ebay and managed to find a complete bottom end, including, gearbox, crank clutch etc. Result! it might sound a bit cowboy, but i used the good bearings, oil seals and bottom crankcase from the spare bottom end, this meant i got to keep my original engine number, i know it sounds a bit dodgy re-using bearings and oil seals, but i cleaned them up and checked them over and they had very little wear, the bearing is lubricated from the gearbox oil so doesnt wear much at all, besides, these bearings and seals cost an absolute fortune!
Stage 6: Engine Rebuild!
Started putting it all together, looking not too bad..
Stage 6: First Start up!
I have finished the engine, mounted it in the frame, set the timing, balanced the carbs, primed the 2 stroke system, and fired her up, sounds sweeeeet.
Stage 7: Rebuild time!
Ive been busy lately, I bought another bike for spares, not sure of the model, but loads of useful spares, I have used the rear mudguard, front mudguard, front wheel rim, and there will be other bits and bobs I can use. The front wheel has been rebuilt using new spokes and the rim from the donor bike, I have cleaned the forks and fitted new seals, I have loads of wee jobs still to do. here’s some more pics taken tonight. Cheers
Stage 8: Painting!
I ended up using the tank from the spare bike, it was a real mess to look at, but inside it was like brand new, not a bit of rust at all, so I set about stripping the decals and paint, filling the dents, and painting, The red colour I used was a special mix bought from halfords! It has a very slight copper glow to it i thought it looked the beez kneez and was as close to the original i could find. i should have taken a picture with the laquer applied!! doh! ohh well, you can see the tank below in the finished pics.
Stage 7: finished!
Really enjoyed looking through your pics and video of the rebuild-you’ve done a great job.
It’s great that you take the trouble to post up so much info, keep em coming.Cheers,Mick.
Enjoyed the whole project. The bike sounds like it should in the video….and that’s good too.
Why have you decided to paint it in the K (1973) colour scheme rather than one of the M colours ?? Just curious…..
Best regards,
Rick
I just liked the colours at the time :) i was planning on keeping it so just my prefrence really.