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Project GT250 Fun and games!!!!!!!!!!

Discussion in 'Your 250cc Projects' started by Damian_74, Oct 20, 2019.

  1. Damian_74

    Damian_74 Member Premium Member

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    Tomorrows Project......

    Fitting Kawasaki parts to the Suzuki!

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  2. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Ahhh. Check valves , I Found a guy who sells repop Suzuki ones in the uk, but your option of using Kawasaki ones seems a better option amongst the Suzuki community , let us know how it does
     
  3. Damian_74

    Damian_74 Member Premium Member

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    Could not have been easier!

    I was looking at the reproduction valves in eBay, had read mixed reports but then came across a post about the Kawasaki check valves. Part No. 16128-009.

    From memory it was $109AUD from the local Kawasaki dealer (4 weeks ex Japan) vs $96AUD delivered from the UK for the eBay valves.

    Looking at the new Kawasaki valves against the old Suzuki ones - fairly sure they are the exact same part - Suzuki never listed the valve on its own as a spare.

    Fitting was easy - I did follow the instructions form the eBay valves.
    https://www.1970sjapmotorbikeparts.co.uk/checkvalveinstructions.pdf

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  4. Damian_74

    Damian_74 Member Premium Member

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    Minor backward step......

    The splines on the gear change shaft are worn as expected for bike of this age. I have seen a few NOS ones for sale in the past but the vendors all wanted silly money - found this one in Australia for $100.

    So.........side cover and clutch back off......am confident that that will be the last time....might even tempt fate and fill up the gearbox with oil!

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  5. Stubanger

    Stubanger Well-Known Member Premium Member

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    Just got caught up on this resto, top quality! Did I sell you the replacement air box in November?
     
  6. Damian_74

    Damian_74 Member Premium Member

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    Set the timing with a dial gauge and test lamp - was surprised to find that the marks on the flywheel are near spot on - I'm not even sure what bike the flywheel and generator came off?

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    Everything has come to a grinding halt........sent the tank off with the side covers so the painter could match it and still waiting for the chrome (he was very vague about finish date).

    Remaining items....

    Cleaning up the dash best I can - there is another 2nd hand set on it's way from the US that appears to be in better condition.
    Waiting for one of the bushings for the front brake line before I can bleed it
    Self locking nuts for engine bolts still on order.
    Mirrors should be in at Suzuki this week
    Painter at the end of the week with some luck???

    Might even try to give it a start when the tank comes back!

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  7. Damian_74

    Damian_74 Member Premium Member

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    The regulator rectifier set up on the 70's Jap bikes was sad at best - actually the entire electrical system is sad but still better that what was on offer from the British - LUCAS (AKA prince of darkness)!

    Found a cheap 2 phase RR on eBay. Had it wired on on the 74L when it was running, so it and the entire loom is now fitted to the 77B. Decided a little bracket was needed, it's tucked up under the seat. Should still get plenty of cooling air and is well hidden to keep the rivet counters happy.

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  8. Damian_74

    Damian_74 Member Premium Member

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    All the Fitter and Turners turn away now!

    Committed a lathe crime today - turned timber on a metal lathe - I promise to clean and lubricate all the ways.

    Needed some way of holding the bezel ring in shape as I opened the gauges. Trying to make a half decent set from two.
    Lump of hard wood machined to size, lined with felt - worked well enough.

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    The gauges aren't perfect - but funds are starting to run out so it will have to do!
     
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  9. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Nicely done.
    I put a piece of paper across the bed of the lathe when I have to do any woodwork. Helps with the clean up.
     
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  10. Damian_74

    Damian_74 Member Premium Member

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    It's Alive!

    Started fourth kick (after I turned on the kill switch).

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  11. Damian_74

    Damian_74 Member Premium Member

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    Clearing the Mozzies from the neighbourhood.

    LOTS of smoke - I did have 30:1 premix, oil pump on max and generous amounts of assembly oil!

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  12. Damian_74

    Damian_74 Member Premium Member

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    Painter came back with the colour matched side panels - he did a Lovely job!

    Now just waiting on the chrome, then I can take it for a test and tune (clear the oil).

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  13. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    congrats mate, she is bloody gorgeous - 2 stroke ride soonish ?
     
  14. Damian_74

    Damian_74 Member Premium Member

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  15. Damian_74

    Damian_74 Member Premium Member

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    Your GT is looking the part too!

    Unfortunately will have to wait - will be lucky to get the chrome back before I head back out to sea.

    Lock in a ride for end of March - might stop raining by then!

    It is complete torment not having the mudguards - tempted to chuck on some old ugly ones that I have but with everything else so shinny it would hurt too much.
     
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  16. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Nice work, my neighbour would love living next to you.
    Think it's about time i started and ran one of my 2 stroke's again...
     
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  17. Damian_74

    Damian_74 Member Premium Member

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    I actually like my neighbors (most of them - there is always one!), make sure they are all out when I start old smoky.
     
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  18. Damian_74

    Damian_74 Member Premium Member

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    It's getting closer to the door - nervous transfer to from the fixed to lift bench!

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  19. Damian_74

    Damian_74 Member Premium Member

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    Finally got some chrome!

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  20. Damian_74

    Damian_74 Member Premium Member

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    DONE.............................

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    Unfortunately I'm back to work for a month so no time to register and tune.
     
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