Project GSX250F Across

Another mini-project. $750 for an unregistered 1996 Suzuki Across.

It was in pretty good condition and had some work done already so calling it a project seems an overstatement.

Previous owner had put in a good battery, removed and cleaned the carbies (along with new seals etc), front and rear brake pads, cleaned fuel tank and put new fuel lines and in-line filters on the bike. Fork seals were leaking on one side and tyres were shot.

It started up straight away, ran smooth. I figured it was worth the price and the risk.

Got it home and so far I've changed plugs (think they had recently been done by previous owner, so I have spares now) and also replaced oil and filter. Rear tyre replaced and front about to be done (noticed broken fork at pinch point).

Was going to take the forks out to do the seals. Now I will find a replacement pair, do the seals in those and then swap them for forks on the bike now

Pics are from Gumtree ad

 

Not sure what problem was with those original pics. Looked dusty but didn't present that way when I checked it over. Might have hade a wipe down.

Here is a current pics that show condition a bit better. No major gravel rash, a few small scratches on fairings like it fell over on stand.

The timber frame is there ready to support front of bike when I remove front wheel/forks

 

It helps having a very understanding wife. Who am I kidding, I'm single

 

Following threats of being reported to the Royal Society of Automotive Engineers for a half-assed job on the timber frame support, and the possible cancellation of my membership, I decided to reconsider my approach.
Here is my alternative

 

I was obviously so proud of my efforts that my subconscious loaded the photo twice

 

As, the chef's say - here is one I prepared earlier. I made it a few months ago to lift the engine for my ZR-7 project. Didn't think it was tall enough for the Across so tried the timber option. Luckily it was just tall enough.

 

Success - frame supported with wheel high enough. Wheel out ready for tyre change. Just need new forks to arrive. I will leave old forks in place with support blocks until new ones arrive. A belt and braces approach.

 

Update:
Front tyre has been swapped and wheel balanced. Then it was a wait for the replacement forks to arrive. They turned up yesterday (good price and fast shipping from Chris at MotoREcycle).

Next step is to replace fork seals and dust caps in the replacement forks before installing them.

I've removed the right fork to use as a strip down test (and check the fork damper tool I'm about to make works properly). Old fork is middle one

 

Fork Damper Tool made and works a treat. Youtube and a few forum posts gave me design idea and suggested dimensions.
For anyone else needing the specifics:
60cm length of 22mm od tube (3mm wall), cut into 2 pieces, 45cm and 15cm.
16mm hex head bolt (24mm spanner for head)
Insert bolt into 45cm piece of tube and weld in place (keep weld clear of hex head)
Weld top handle using 15cm piece at other end of 45cm piece.
Once I had the fork stripped down enough I was able to place tool in fork to lock damper while I used 8mm impact hex in battery powered 1/2" drive impact driver.
Note: I did use 1/2" air impact wrench to loosen allen bolt first. I was hoping it would be enough to loosen bolt without making the tool. Damper kept spinning, so tool needed. Can't be sure battery driver would have been enough without it.

 

Gotta love the weekend when you can get stuck into a project. Forks dismantled ready for cleaning.

 

All ready for reassembly. Will do a partial reassembly now, no fork oil in today so the threadlock on bottom bolt/drain plug has overnight to set. Then finish the rest off tomorrow and get then back on the bike.