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Cafe Racer Project (kiffsta's old GT250)

Discussion in 'Suzuki 250cc 2 Strokes' started by napolian_was, Feb 12, 2013.

  1. napolian_was

    napolian_was Well-Known Member Contributing Member

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    look up sr500 seat or cafe racer seat on ebay and you'll find it.
     
  2. napolian_was

    napolian_was Well-Known Member Contributing Member

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    hey guys now for that update, exhaust is done and i'm over the moon about how it turned out. i was starting to get worried about how the chambers were going to fit up with out interfering with the shifter and brake. i ended up taking out the center stand doing a little bit of a chop to the pipes and it ended up fitting under the bike like a bought one. new coils and made a bracket for the key and oil tank. got lots of wire plug's and other component's on the way so a wiring loom should be in the next update. sad to say the engine is still as empty as a beer at the end of a friday night.

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  3. Doodler

    Doodler Member

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    Great looking project. It should be done and on the road by now? I assume that's why there haven't been updates;)? I just started tearing a 74gt250 down yesterday and have the bug! The one I've got runs great so I won't be doing a lot of the engine/gearbox stuff but I plan to lose the points. BTW I had an idea for a really cheap and awesome battery that you might find useful. I have an old cordless drill that's been retired, 14.4v LiIon type...I'm going to bust the cells out of the case and use them in the bike, it will be really easy to lay the cells flat and hide them under the seat or anywhere! My goal/inspiration since I didn't pay anything for the bike (it's been in my family since new and has been in my shed for about 7 years) is to build a 100mph bike for under $100. I know it's going to take some creative re-purposing and fabrication but that's the part I like. I haven't decided yet but I'm leaning toward an army canteen or a metal water bottle with a bicycle mount as the oil can. Love the cap you put on the tank too.
     
    Last edited: Apr 22, 2014
  4. napolian_was

    napolian_was Well-Known Member Contributing Member

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    haha the work continues, i had not touched it for a long time as i was waiting on the crank and had other projects to distract me. about a month ago i decided that old buddy was never going to do the crank for me, after a bit of stuffing around i got it back with all the bits. i was given a number for the for the best guy in the bizz and that where i stand now.

    i sent it over and he said if we are going to do it we need to do it rite. so new con rods it is, its much easier and cheaper to get the later model rods from the gt250m/a/b/c they fit but you need to use the later model pistons,(cant use pistons i had already bought) so rods and pistons were ordered last weekend. soon as i get the rods the crank should go together soon after and everything should start moving very fast after that.

    as it sits now:
    [​IMG]
     
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  5. napolian_was

    napolian_was Well-Known Member Contributing Member

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    finished putting the bottom end together tonight with my rebuilt crank and every bearing and seal replaced in the gear box. cant wait to get her in the bike and fired up.

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  6. Phil

    Phil Senior Member Premium Member Contributing Member

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    Good to hear from you again, it's been awhile. Guess there is light at the end of the tunnel at long last. Great photo's, she should be firing into life again soon, keep us posted. Good to have you back.:thumb_ups:
     
  7. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    WOW, nice work mate, cant wait to see her on the road
     
  8. risky

    risky risky

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    looks very neat.
     
  9. Mclaren

    Mclaren Well-Known Member Contributing Member

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    Looking smick
     
  10. Moo

    Moo Plodge Racing!!!

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    wow mate nice build, the GT looks well also.

    looking forward in see the final product!

    good on ya!
     
  11. napolian_was

    napolian_was Well-Known Member Contributing Member

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    put the bottom end in the frame this arv, ready to start putting the clutch and stator side stuff together then move on to the top end.

    [​IMG]
     
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  12. napolian_was

    napolian_was Well-Known Member Contributing Member

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  13. FZRdad

    FZRdad Dirty Hands

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    Incredible transformation!
    I had 3 of these like 30 years ago and rode one daily until I found the RD of my dreams.

    I kinda wish id kept them now.
     
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  14. cal

    cal Well-Known Member Premium Member

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    im using the exact same seat on my current Pub racer build!! :thumb_ups:
     
  15. napolian_was

    napolian_was Well-Known Member Contributing Member

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    its been 8 months and i should really start the wiring loom, its the last major thing other than the tank. finished the ignition wiring today.

    [​IMG]
     
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  16. napolian_was

    napolian_was Well-Known Member Contributing Member

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    rear wheel set up with spacers and set the chain up. loom is about 90% done and got some uni's
    [​IMG]
    [​IMG]
     
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  17. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Coming along nicely. Other members take note of the mudguards/fenders they look like they belong there, form follows function. :)
    If I may offer a suggestion Napolian, the chambers look like they need to be tucked in and kicked up a little. This is not a difficult task if you can gas weld or have someone local that can do it.
    Also vibration mounts for them would be a very good idea. There are many different versions but something like the versions in the image are usually available from engineering supplies/FleaBay and are not expensive. I recommend using two 6mm versions.
    [​IMG]
    cheers
     
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    Last edited: Mar 3, 2015
  18. napolian_was

    napolian_was Well-Known Member Contributing Member

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    loom is done, first one i've made from scratch and i'm very happy with it. just got the tank, sort out the gear leaver and the long road of tuning to go.
    vibration mounts sounds like a good idea i'll have the check that out, i'm not too worried about tucking them up, they've got good clearance. if i have issues down the track i'll have to change it.

    little pre paint photo shoot

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  19. napolian_was

    napolian_was Well-Known Member Contributing Member

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    i'm back!! after purchasing my first home about a year ago i had to slow down with most thing's bike related and with no shed all my fund's were directed at getting one built. two months ago she went up, so i've been in full swing in getting it set up.
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  20. napolian_was

    napolian_was Well-Known Member Contributing Member

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    i really want to get this one done by the end of the year, so i've made a list and going through one by one.

    shifter is done, spline was stuffed so i cut it off the leaver and welded on another.
    rear brake switch is done.
    having some trouble stopping the oil tank from leaking, no matter how much sealing i do it still seem's to escape. it's not leaking real bad so i'll deal with that later.

    now for the big problem the carbs, well the left carb to be more specific. when i first got the bike i was cleaning them out and couldn't get the pilot jet out and totally striped the hell out of it. after trying easy out's and drilling i ended up doing more damage beyond repair.
    i ended up putting them back together for another day and lucky me that day is today, so my option's were track down and pay top dollar for something in not much better nick or get a new pair.

    i tried my luck with the second option, i got myself two mikuni vm24's and am waiting on some inlet robbers, jet's and throttle cable spacers, will keep you up dated.
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