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My bike and upgrades.

Discussion in 'Hunter 250cc' started by tmy87, Oct 17, 2013.

  1. Johnnie347

    Johnnie347 Active Member

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    Cheers for the quick reply, hows the lil bike holdin up, have you had any of the tank, wiring or gearbox problems these can have? I've been hit with 2 out of the 3, hence the engine change. Will check out Ebay.
    Thanks again :)
     
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  2. tmy87

    tmy87 Active Member

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    I have had a couple of small problems. Rear brakes locked up on me, turns out they have to be pressure bled with the nipple facing as far down as possible. The speedo is about 20k out and after 110 it flicks back n forth. No problems with the fuel tank but I had it upgraded to a larger tank. Also had the pegs moved back. Rides awesome now. When I work out how to put pics up again I will upload the new upgrades.
     
  3. tmy87

    tmy87 Active Member

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    Have you done any research as to how well the gs500 will fit?
     
  4. tmy87

    tmy87 Active Member

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    Found a way of uploading the new pics of my bike. ImageUploadedByTapatalk1414021351.853376.jpg
     
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  5. Johnnie347

    Johnnie347 Active Member

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    Welcome back to black
    The 500 fitted beautifully and fills out the frame well. I welded 2 vertical braces under the seat and cut a horizontal brace out to clear the suzukis oil filter for removal. Still have to fab exhausts. But that won't b to hard. I bought a 2010 write off complete with wiring to do this and this is the 1st time I have ever attempted something like this. Its all happened trouble free so far. Interesting piont is the handlebar switches/assembly are identical (no choke lever on yours but the words are there) Hunter must have sourced them from the Suzuki parts bin.
    Anyway happy riding to you.
     
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  6. tmy87

    tmy87 Active Member

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    Thanks mate. I think black compliments the bike much better.

    Good to hear that Suzuki is similar in wiring because I'm looking at putting a gsxr750 engine in mine so will keep that in mind when choosing an engine.
     
  7. Johnnie347

    Johnnie347 Active Member

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    Not sure I would go that big. The frame is only 1.2mm thick mild steel and yo7 should stay with a twin engine. The 750 would be a lot wider, heavier and more torque than the little chinese frame could handle. Also nothing elee was similer wiring wiee, I wouldn't try to mix n match and I 2ouldnt know if the 500 and 750 are the same in any way.
    But after saying all that I didn't know a 500 would fit till I did it. lol
    Build ur dream buddy
     
  8. tmy87

    tmy87 Active Member

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    Thanks mate. Good point with engine size and weight. I was going to measure one because I would like to keep it looking stock. A bloke at hogs said he would be able to fit a 1200 triumph in it for me but would cost more than the bike is worth that is why I am looking at doing it myself with a smaller engine. Are you able to post some pics of your build so I can see how it turned out.

    Cheers
     
  9. Johnnie347

    Johnnie347 Active Member

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    I can take some close ups of the new mounts. My truck mechanic gave me the use of his workshop, material and an experienced welder for 2 days and $200. It wouldnt take me 2 days next time but im a learner at this stuff. There's not many businesses that will do that these days. I sat the motor in, marked where it lined up with the frame, cut a few tabs from 3mm steel. 2 for the front, 2 on the bottom, bent 2 vertical tubes near seat (unlike me make sure u allow for the removal if seat bolts. lol) welded grade 8 bolts for the 4 points of contact with the engine, with a removable panel to aid engine removal. You have to remove the frame loop under seatvand set engine as far back as possible, even more than I did, not certain but u may even reuse exhaust.Wiring fits but doesn't go in frame unless u splice it. (Dont mix in the hunter stuff).I'm using the suzuki petcock and fuel tap ( take out EFI pump but haven't nutted it out yet. Not because its hard but beccause I'm lazy. Suzuki remote oil cooler fits easy with the tubing at the banjo ends bent properly (not by hand)
    Anything else u want to ask let me know.
     
  10. tmy87

    tmy87 Active Member

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    I have already modified my seat to 2 springs at the rear rather than the single shock so guessing I will be right with that?

    Why does the engine need to be mounted as far back as possible?

    When you say don't mix in hunter stuff when it comes to wiring I guess you went all Suzuki wiring up to starter, ignition, etc?

    Why don't you need the efi pump?

    Cheers.
     
  11. Johnnie347

    Johnnie347 Active Member

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    I could havevgone back another 30mm for more chain adjustment and I think the original pipes would have run inside the frame as original. Now I will have to use suzukis manifold with one hunter exhaust or fab a pair that run around the front of the frame to the original mounts.

    Yep suzuki wiring all the way to the LED indicators. Suzuki ignition, headlight plug,switches, stand safety switch...everything

    Hunter Efi pumps too much fuel to the carbs. Fab a plate using efi as template. Screw in fuel tap.... etc etc
     
  12. tmy87

    tmy87 Active Member

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    Side mounted my gauges yesterday. Also have found a gs500f engine to go in soon. ImageUploadedByTapatalk1415747295.613587.jpg
     
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  13. Johnnie347

    Johnnie347 Active Member

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    I'm liking your ideas....well done mate
     
  14. tmy87

    tmy87 Active Member

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    Cheers mate. I reckon your use of army disposal saddle bags is great and might have to steal that if you don't mind. Also for your interest I did some research and if you can manufacture engine mounts to connect to the original mounts and engine it will fly through certification for rego.
     
  15. Johnnie347

    Johnnie347 Active Member

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    20141207_094049.jpg 20141207_094107.jpg 20141207_094115.jpg 20141207_094140.jpg 20141207_094209.jpg 20141207_095034.jpg 20141207_094351.jpg
    Wiped off the dust and got her going for a quick ride to the beach, the gears are reversed but i got used to that real quick, heaps more grunt, smoother changes of the box and sat on just over 3000rpm at 70 k's in 3rd (never went over that cause i am mindful of no oil cooler). This is how hunter should make them.... very happy with the swap. Still have to fab up an exhaust. Before you go cutting though i would recommend NOT doing the swap, i did it because my gearbox was stuffed and the wiring was bad, i dont ride it much and it doesn't worry me that the bike now isnt really worth anything. Yours IS working and worth something, if it does give in then go ahead, its an easy swap :) EDIT... the bags were bought from ebay off a Texan
     
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