Suzuki GSX250 Cafe Project

As of now, it doesn't seem like I will need to tear the engine down. I discovered the hole in the crank case only goes into the starter motor compartment. I removed the starter motor, to get better access to the hole. I'll get the area all cleaned up and have it welded. As for the screws with the stripped heads, I have done everything I can. Tomorrow, I am taking it to a small motor guy who said he can get them out. I bought some replacement screws, and will get them all replaced. My next step is to get the motor all cleaned up from grease and grime, paint it and detail it.

My main concern now is how to mount the electronics and battery. This is a very small frame, I just want it to look clean.

 

Ok, so, I got the stripped screws replaced today. Found some replacements at the local nut and bolt store. I found out this week I do not need to tear the engine apart to fix the hole in the crank case. The hole is actually in the starter motor compartment. So, I will get it degreased and cleaned. Then I can get it to the welder. Then it's on to further cleaning, detailing and painting the engine.

 

A thrown chain, at least that's what it looks like.

 

I was thinking about taking photos of it, but I forgot and took it to the welder today.

 

Ok, the project is still going. Just been rethinking the seat and how to fit all the electronics. Plus, my battery hasn't shown up. I have also been working on a GN250 that I picked up for cheap, just needing something to ride around.

 

Thanks for that. It does give me some ideas. I am hoping I can fiberglass a seat that will allow for the battery and electronics to be mounted underneath. I will need my metal guy to make a plate that can be welded just below the frame.

 

Well, working on getting this project back on track. I have an appointment next week to have a battery box and plate welded up to mount the small shorai battery and other electronics. I will also see if the guy can make me a seat pan out of some rolled steel. I am working on getting some components bolted back onto the engine. After that, I may pull the top end off and make sure everything is good up there. One question I have is, what would you all recommend for some mikuni carbs? I have seen it posted that some mikuni slide carbs would suit a project like this. I am not sure which size to go with and what mounts may be needed.

Thanks.

 

Well, I am working on getting some progress done on the GSX project. I just dropped the frame off at a fabricator/welder to have a battery box, electronics mount plate and a seat pan fabbed up. I hope it all turns out the way I want. At that point I should be able to get the motor back in the bike and start getting it wired up.

However, I do have a question. I am working on getting the clutch back in the bike, as well as the stator rotor. These areas spin, so what is the best way to get the bolts torqued down. I can use a battery powered impact, but not sure this is a good idea.

I am also looking for some future upgrades. I am thinking I may look at changing the carbs to Mikuni VM style, but not sure which ones to go with. Is there one that will fit the stock carb mount on the engine?

Thanks for any info you all can provide

 

Awesome, thanks for the reply. I was pretty sure that was not the way. I'll just wait to get it back in the frame.