Project ‘97 Suzuki Across Project

Not too complicated really.
You have the 2 fork legs and discs already (1 from each bike). the spacer can be made by any competent machine shop easily from hi tensile aluminium and you need to source the 2 brake lines and the splitter as well as a larger Master cylinder... I dont see it as being any more difficult than what you are attempting with changing your fuel tank etc... it will cost a few $$ but overall it is a cool modification just like @kiffsta said... but each to their own level of comfort in modifying / upgrading their bikes.

 

Most of the pic's of the GSX250F new show the front brake on the right hand side

Look's like the hub would be easy enough to drill and tap to suit the 2nd disc




Then using another fork tube with the caliper mount would work,
you also need new brake line/s, a brake line splitter for 1 line into 2, and a bigger brake master cylinder.
But the only problem i can see is you wont have the larger hole in the bottom of the new fork leg to put the flanged head of the axle through, and wont be able to clamp the axle in the fork.
The caliper side fork is threaded and the other side fork clamp's onto the thicker flanged part of the axle.

 

Single disc bikes usually use 320's so fitting two on to an across might be more effort than it is worth and Sukiman is just feeling his way with all this bike work.

 

Probably is overkill as the discs are rather large... but it would look pretty cool.
I cant see properly from the pics on the Orange bike but it may be the axle setup is the same. I have seen it done before and I was oversimplifying the work required above... (since edited as well).
I am sure there are a number of reputable shops around the Newcastle area that could do the work but it is probably expense that @SukiMan doesnt need or want right now
Should be a nice little runner when finished though.. hmm Orange... it definitely will stand out

 

That's what is listed for the GSX250F Across
The centre bolt push's against the flywheel bolts' head (with the flywheel bolt loosened a few turn's first)
Is that just your picture or do you have the threaded cylinder on an angle compared to the flywheel hub ?

Hold the threaded cylinder squarely against the crank and turn it anti clockwise, when you feel it click that's the 2x starting thread's going over each other, do it up from there.

If it still doesn't fit measure the thread diameter on the flywheel hub and get onto the seller who you bought it from

 

Does the large part of the puller actually screw onto the threads of the flywheel?
You need to have the retainer bolt for the flywheel loosened otherwise it wont work.
Can you show us what the end of the bolt that came with the puller is like... it should have a taper and like a ball end on it.

 

Can you link the one you have just ordered on here so we can see the differences?

 

Yes the flywheel bolt need's to be loosened a few thread's (say 3 full turn's out) first before fitting the puller, so that the centre bolt of the puller has something to push against.
Once the flywheel start's to come off then you need to take the puller off and wind the bolt out the crankshaft a bit more, or if the flywheel is loose then you can take it off.


You say the cylinder section doesn't screw onto the flywheel, but it look's like it does in your picture above ??



It was possibly the chinese one from Jono794 on ebay ?
https://www.ebay.com.au/itm/FLYWHEE...hash=item1ea8f7e7ad:m:mIXHwXjOntjlZdfVIlrzFbQ



Message him and let him know it doesn't fit the Suzuki Across that it is listed for, and ask him what you need to do to get a refund ?

Have you worked out what thread your flywheel has yet as you will need to let Jono794 know

 

So is the puller left hand or right hand thread?
To check this, try turning the puller the 'wrong' way (ie anticlock wise when looking at the flywheel) and see if it grips the threads. If it just slips off, then try the other way to see if it grips. Also check on the good engine to be sure it is the same thread.

 

If you have ordered this one... it is identical to the one you now have... ie 30mm x 1 RH female thread... so you are going to end up with 2 of them... one a good quality item.. the other from Qld... via China

There are not may flywheels that come off first hit... you could try putting some heat on it but it is a delicate balance of how much to put on.
I must admit.. I am a little concerned that your mate is bringing pry bars.. I dont think I would be using them in conjunction with the puller... actually.. I wouldnt be using them at all... let us know how you go with it...

 

Why order another puller with the same thread?

Have you measured the thread size on your flywheel to check it is correct ?
The pitch also need's to be the same so make sure you check that too

Watch this video, it show how to get the flywheel off a similar set up to your's
Note that the flywheel retainer bolt is loosened a few thread's before the puller is screwed on