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Project Another GSX 250 CafeRacer

Discussion in 'Your 250cc Projects' started by Dave H, Dec 22, 2013.

  1. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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    Old bikes ...dont u just luv um !

    Ive missed all your recent posts Dave ....great to hear u got the racer out on a run ....:thumb_ups:
     
  2. Dave H

    Dave H Active Member

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    My Bike:
    1981 GSX 250, '83 GSX 750ES, '08 DL 650, ' 89 ZXR400 race bike
    As is apparent, the dark marks are actually depressions in the basket caused by the plates.
    One side is worse than the other, but with the judicious use if a file and some fine emery the polished out altogether. I slid the plates up and down several times. I felt no drag or inpedement.
    Hopefully this is a cure.


    10014681_10152882231959368_8543496907958788506_n.jpg
     
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  3. Dave H

    Dave H Active Member

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    My Bike:
    1981 GSX 250, '83 GSX 750ES, '08 DL 650, ' 89 ZXR400 race bike
    Well the bike is now in bits spread across the garage floor.
    The swing arm bearings hadn't seen grease since new and are absolutely fragged, as are the bushes they run on.
    The spacer was also missing. New bearings $15 each but no bushes, so I shall make my own. Getting them case hardened or hard chromed could be an issue.
    Pulled the wheels apart to replace the bearings, the spokes on the rear had several bent, so the'll need to be replaced.
    The front might as well get done too.
    Once the tires were removed, I found the rims were rusty inside, so wire brushed off the rust and will pain with the appropriate anti rust paint.

    As stated Old bikes are full of surprises
     
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  4. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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    If we all had new bikes we would have nothing to do and nothing to bitch about and the forum would be full of ... "gee I went for a great ride today"

    hang on a minute .........:oops:
     
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  5. Phil

    Phil Senior Member Premium Member Contributing Member

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    My sentiments exactly, lets ride.:thumb_ups:
     
  6. Dave H

    Dave H Active Member

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    My Bike:
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    Swing arm bushes and spacer got made today, the bushes will get case hardened through a mate in the business.
    So a bit more is accomplished.
    My gasket set from the UK arrived too, so now I can begin to reassemble the engine.


    Despite the shitty weather last Sunday I went for a ride to look at old bikes, even took some photos.
    Not too many 2fiddys there though

    20140504-DSC_0085.jpg 20140504-DSC_0113.jpg
     
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  7. Dave H

    Dave H Active Member

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    Motor assembly underway, new rings, valve stem seals, gaskets. Valves lapped and checked.
    Started to polish the cases, started to fill all the little dings in the tank, really labour intensive fun
     
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  8. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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    Major progress there Dave :thumb_ups:

    I missed that previous post .....hmmmm the Norvin :Drool:
     
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  9. Th3_Huntsman

    Th3_Huntsman Senior Member Premium Member Contributing Member

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    ^ as did I GI. Same answer:Drool:
     
  10. Murdo

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

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    Good to see you getting some 'therapy'. :lolsign:
     
  11. Mclaren

    Mclaren Well-Known Member Contributing Member

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    If u want to harden can do at home with a oxy and tin of oil think it 240c first treatment then 140ish second time
     
  12. Dave H

    Dave H Active Member

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    My Bike:
    1981 GSX 250, '83 GSX 750ES, '08 DL 650, ' 89 ZXR400 race bike
    So the re-assembly is going in the right direction, motor has had new rings, valve stem seals, valve re-lapped ( they didn't need grinding). I have replaced the clutch fibre plates, a much smoother action now.
    The motor now complete and repainted. My son gave me a hand to lift it back into the frame. Much easier than doing it on my own.
    A new rear guard has been fabricated using 5 mm acrylic sheet and fitted to the existing half.
    I'm making progress, slowly. But considering there is no time frame, I think its all good.

    10405591_10153139903699368_1421026754904506031_n.jpg 10301957_10153139903569368_5953160779909574116_n.jpg
    assembled motor, waiting for polished parts
     
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  13. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    WOW, that motor has come up a treat.. Definitely subscribed to this thread :thumb_ups:
     
  14. Phil

    Phil Senior Member Premium Member Contributing Member

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    Love your work Dave, curious about what exhaust you intend fitting?? If the engine is anything to go on, you are going to have a very special machine on your hands. :D Sure I speak for all, can't wait for more.:thumb_ups:
     
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  15. Dave H

    Dave H Active Member

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    More progress has been made, the tank has been filled and primed ready for paint, as is the front guard.
    Replacement stator has been purchased from a wreckers, ( tested and ok'd). Fitted up this afternoon, had to change the plugs to match the reg ones. So the motor is almost complete.
    I have been spending the cool evenings in the garage sorting out the wiring, I have removed surplus wires, replaced a couple of burnt ones. Tomorrow I will check the battery and test the electrics.
    I will post some progress pictures shortly.
     
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  16. Dave H

    Dave H Active Member

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    1981 GSX 250, '83 GSX 750ES, '08 DL 650, ' 89 ZXR400 race bike
    Well I tested the electrics tonight, apart from a loose connection for the front brake all works well.
    The horn sounds like a Noddy car, a bit of a joke as a warning device. Might have to get another Stebel Nautilus, at 137 db it should be loud enough. Very fitting for a small bike. :)
    Been making a list of "to do" jobs. there is less on the page than when I started.
    Hopefully I can get some decent photos tomorrow.
     
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  17. Phil

    Phil Senior Member Premium Member Contributing Member

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    One would certainly hope the list is getting shorter, you've covered much ground already. Can't wait to see some photo's. Good luck with it.:thumb_ups:
     
  18. Dave H

    Dave H Active Member

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    I promised some photos, excuse the quality, I used my phone.

    As it sits at the moment. Waiting for the new rims, the hubs have new bearings, and the new spokes are on the bench.
    The next big job will be the paint, I'm undecided whether to do it myself with rattle cans or pay a pro to do it.
    It just a question of dollars V confidence, I suppose.
    This week I hope to turn the motor over, initially by hand, then with the starter motor, due to the fact it has be thoroughly cleaned and there is little oil in it.
    Then I hope to start it up to check the timing and carbbies


    20140616_112955.jpg 20140616_113034.jpg 20140616_113052.jpg 20140616_113108 (1).jpg
     
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  19. Ben Mulligan

    Ben Mulligan Well-Known Member Premium Member Contributing Member

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    Mate its looking SO much better already. A bit of care and attention can do wonders! You've inspired me to get back to it
     
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  20. Dave H

    Dave H Active Member

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    Well its been a while, the GSX has sat in the garage under a cover while I accumulate some $ to get the paint.
    Fired it up last week for the first time since the engine rebuild.
    Well I thought it was ready, but no the timing was out. So off came the valve cover to find the fault.
    The inlet cam was out by 1 pin, bugger!
    Once reset and cover replaced, static checks done and "Voila" it lives.
    Set the carbys and it ran quite nicely, albeit a bit smokey
    The smoke came from the crankcase breather and of the recently painted exhaust.

    Fired it up again yesterday, no smoke anywhere, no leaks either ( didn't expect any).
    Runs quite well, but the proof will be when it goes back on the road.

    Now to get the wheels back from being re-laced with new spokes, put new rubber on and paint the tank and front guard.
    Hopefully it will be done by the 8th of this month in time for the "Distinguished Gentleman's Ride"
     
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