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Project Qs GSX250 Cafe Build

Discussion in 'Your 250cc Projects' started by PFAQ, Dec 20, 2015.

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  1. PFAQ

    PFAQ Active Member

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    Hi All,

    My name is Q.

    I have recently purchased a pair of Suzuki GSX250 1980 from a member on this forum (Frank). Unfortunately.....for Frank he managed to fix the sparking issue as i was ready to pick the bike up....(It now runs and sounds amazing).
    The reason why i want to build a cafe racer is because i have finished building my 1995 Honda Civic with a new heart transplant putting down roughly 150kw atw.

    [​IMG]

    [​IMG]

    But not only that; normal registration for my R6 cost an arm and a leg so the next logical thing would be to get a club registration for a bike (this is where i fell in love with the cafe racer).
    I want to build something that i will appreciate and hang on to for as long as i can. I was really leaning towards getting a Honda CX500 (Honda fanboy) but my friends raised very valid points to go with the 250.

    Having sold my R6 earlier this year, I have been itching to get back on a bike.... my mum didn't like this idea at all when i came home with the newly acquired bikes.... nonetheless i wont be letting anything stop me as i have already started tinkering.

    [​IMG]
     
    PFAQ, Dec 20, 2015
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  2. PFAQ

    PFAQ Active Member

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    Melbourne's weather definitely lived up to its reputation of having 4 seasons in a day. When i quickly got home i unloaded the trailer and then the tools game out.

    These were the newly acquired bikes sitting in its new home.


    RUNNING GSX250

    [​IMG]

    DONOR GSX250

    [​IMG]

    I didn't waste any time and tried to get as much done as possible.
    All seemed quite simple removing the parts then i discovered this...... custom wiring and extentions were made from one of the previous owners. This looks like i will be needing a new loom and possibly the correct CDI unit.

    [​IMG]

    Removed the rear shocks and figured that i would need to purchase some new springs with a length of 11". Standard sits at 14"
    Will be looking for some options so if you guys can assist with brands that you have had experience with that would be stella!

    [​IMG]


    [​IMG]


    Can anyone tell me what plug this is. Discovered this behind the headlamp and was not plugged to anything and concerns be as one of the wires were cut.......

    [​IMG]
     
    PFAQ, Dec 20, 2015
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  3. PFAQ

    PFAQ Active Member

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    Moving along with the stripping of the donor i discovered this line but didn't know how to remove it. I can only assume this is the switch for the rear brake lights......? any ideas?



    [​IMG]

    Frank had a spare tank lying around and who am i to say no to free parts.

    Test fitting the tank and contemplating whether or not it would suit the look of the bike.... still deciding.
    Once the front forks have been dropped i may have a better idea of what i want.

    [​IMG]

    This is how the bike sits before i had to attend to boyfriend duties.


    [​IMG]
     
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    PFAQ, Dec 20, 2015
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  4. Clancy1

    Clancy1 Well-Known Member

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    Go with the older tanks and lift it aboit an inch at the back so it's flush with the frame :) :)
    If you're keen to get rid of a set of header pipes I'm in desperate need of a pair :-(
     
    Clancy1, Dec 20, 2015
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  5. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Welcome to the club Q. I look forward to seeing your build unfold. Cheers Frank
     
    Frankster, Dec 20, 2015
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  6. Evo

    Evo Well-Known Member

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    Nice more GSX's
    There are plenty of GSX projects going on on this site so I'm sure that you will be able to extract all the info you need.

    Correct brake light switch. To remove unhook the wire/rod your fingers is on, hold the plastic threaded grommet/nut and unscrew. Will still turn with rod connected as this enables adjustment.

    As for tank, personnel opinion but my vote is the gray tank. Mine came with the same shape as the red one and I am changing it over. Will need to modify both front and rear mounts to do so.

    Good luck with it but not sure you will need it going by the look of the civic
     
    Evo, Dec 20, 2015
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  7. PFAQ

    PFAQ Active Member

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    I will test fit and see the lines of the body. Really need to decide on the seat but the old tank does make sense.
    I will let you know about the headers because I'm not sure what I should do with them.

    I'm excited for it to finish. I just hope I don't lose motivation.

    I will dummy fit it and get prepping for paint.
    Thanks definitely a learning curve for me
     
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    PFAQ, Dec 20, 2015
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  8. Murdo

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

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    :welcome:
     
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    Murdo, Dec 20, 2015
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  9. PFAQ

    PFAQ Active Member

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    what do you need to get club membership? Heard that I will need to pass a rwc. Do I need mirrors or height clearance to pass?
     
    PFAQ, Dec 20, 2015
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  10. Murdo

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

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    Which club?
     
    Murdo, Dec 20, 2015
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  11. PFAQ

    PFAQ Active Member

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    More so just a general question.
    Is there a club that doesn't need RWC?
     
    PFAQ, Dec 20, 2015
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  12. Murdo

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

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    The Vintage Japanese Motorcycle Club Inc (vjmc.org) is the biggest worldwide one for old Jap bikes, but there will be others around your area that will accept old Jap bikes. For historic rego the bike will need to be 90% as manufactured (changes to exhaust and handle bars etc are ok) and will need a roadworthy or inspected by the appointed club official.
     
    Murdo, Dec 21, 2015
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  13. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Q, not in VIC. Rules changed recently, so all vehicle need to have a RWC even if you're going for Club Reg.
     
    Frankster, Dec 21, 2015
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  14. PFAQ

    PFAQ Active Member

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    All day i could not work with my new project sitting in the garage.
    As i decide what to do next it makes sense to source some wheels for the bike. looking for some Spoke type wheels.

    Thought to myself before i can get my suspension the wheel and tyre choice would definitely make things easier.
     
    PFAQ, Dec 21, 2015
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  15. PFAQ

    PFAQ Active Member

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    Spent the whole night trying to remove the engine. Been watching videos of people throwing their frames? Is there a way of pulling it out with one person?
     
    PFAQ, Dec 21, 2015
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  16. Evo

    Evo Well-Known Member

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    Easy. But has been some time since I have done it (thankfully). Remove all mounting bolts and the plates at the front of the frame. Ensure that all wires and the like are disconnected and carbs are off. Then I think you have to pull the top over to the right side and lift the Bottom left over the bottom left of the frame. It should then tilt out. As I said it has been a bit since I have done it but 100% sure that it always has come out the right side.
    Caution it is heavy on your own. I have a milk crate right next to the bike to land it on.
    Hope this helps
     
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    Evo, Dec 21, 2015
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  17. Murdo

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

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    Lie the bike on its side with some cardboard on the floor and lift the frame off the engine.
     
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    Murdo, Dec 22, 2015
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  18. PFAQ

    PFAQ Active Member

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    I will try this tonight. saw one persons video of them pulling it out so easily.
    i managed to get half the motor out but the top hits the frame and essentially I'm stuck.

    this will be mast resort as i don't really have room to lay the bike on its side.





    been doing some research and how do i get upside down forks on the front end....saw in a thread that one person managed to do it but unsure of the method.....

    <https://translate.google.com.au/tra...tp://www.studiomotor.com/?p=1627&prev=search>
     
    PFAQ, Dec 22, 2015
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  19. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    • Fork length and offset are the two important dimensions to maintain steering geometry
    • When replacing the entire front fork assembly only the triple clamp offset, that determines trail, and the fork length needs to be considered.
    • When retaining the original wheel, the length, triple clamp offset, brake disc diameter, and brake caliper lateral position needs to be considered. It is usually cheaper to move the discs than create custom triple clamps.
    • If custom triple clamps need to be made then the fork centres can be calculated as being equal to twice the FCCM (Fork Centre to Caliper Mount) plus twice the caliper offset plus the the distance between the disc rotor centres.
    • As the offset of the triple clamps increases, the trail decreases. This reduces the self-centering effect and makes the steering more responsive and twitchy.
    • Steering stem and bearing dimensions are not included nor are axle details. These can be custom machined to suit application.
    This from my USD page http://litetek.co/Guide_USD_ForkDatabase.html
     
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    maelstrom, Dec 22, 2015
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  20. PFAQ

    PFAQ Active Member

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    PERFECT!
    Sounds like i need to source a whole front end assembly and looking into machining the bearing.

    i don't think this will be cheap as i have been quoted from a gsxr750 $700 (brakes and front wheel included)
    Asked a few shops and there is one shop that is willing to take this on so and has the forks and triple tree available.
    so i will continue researching.

    I am quite itchy to bite new bits and pieces for the bike as i have been reading Ben Mulligan's build all day. Very jealous of the progress and hope that i can do the same.
     
    PFAQ, Dec 22, 2015
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