Suzuki TS250 Bobber

Sat down this morning with the engine and an old wood chisel and literally 'chiseled' off years of dried up crap, some 1/4" thick.

Note old lounge chair? "One should always be comfortable when working on One's motorbike".

Have been making my own wiring loom as there wasn't one with the bike when I got it.

 

Too hot to do any more on it today, so still 'stuffed'.

 

Thanks Scott.
Nearly finished the wiring loom now, all lights work as they should. Waiting on rectifier/regulator before can finish off and tape up.

 

Started on engine rebuild today. The flywheel took all morning to FINALLY get off and not pretty behind it.
I started with a face puller and hot air gun but made no difference. Just about pulled the bolt heads through the washers before I gave up.

I then used a slide hammer with a 2.5Kg 'hammer' and again it wouldn't move. In a desparate 'fix it or f**k it move' I got the oxy acetylene torch out and had it so hot the glue holding the magnets in started to melt before it let go.

What I found behind was not pretty!

The clutch plates look in good condition, but the basket is badly worn. This would have dragged badly and I wonder what damage it may have caused inside the gearbox.

The only bright bit of the day was that the bore and piston look good and may be able to reuse them.

 

Some progress.
Have replaced the left hand main bearing and seal and crank turns nicely now. Filed all the fingers of the clutch basket and hub smooth again. Fitted new gaskets and have box back together. Had to do another spline job on the gear shaft. Arc/stick welders are great things in the right places, but they do not belong in motorbike workshops to replace missing bolts. This all I had left after cutting off the gear lever.

After building up with MIG welder and doing the lathe/spline trick it was ready to fit.

Spent today bead blasting head and barrel, and honing the bore ready for the new rings when they arrive.

 

New 1mm O/S piston kit arrived, fitted barrel and head and painted. Finished wiring loom with the 6 to 12 volt converter and taped rest of loom. Fitted engine, carb and cables, chain, etc.

 

Spent last Friday making a new pipe for the TS. Used the bits from the pipe I had on my drag bike, and some driveshaft tube from an old Ford Cortina. It may not be the absolute best for performance, but it fits well and looks right. Gave the fuel tank another swish out and put a bit of premix I drained from my Maico in it. New filter into the new hose, choke on and it fired and ran on the third kick. Smiling!


Still a couple of small bits needed (eg horn) that I waiting on the postie for, and I have to find/make a front sprocket cover but otherwise it's nearly done.

 

When it's finished I guess.

 

The last piece of this 'three dimensional jigsaw' is the sprocket cover.

Have been unable to find an original (not surprising as they were plastic and easily broken), so made one today from alloy sheet. Welded a piece of bar to it and drilled through, a couple of folds and a bit of trimming and sitting good.

Counter bored into the bar so the screw sat a bit flusher.

Black paint to match the rest of engine and looking sweet.




Borrowed the plate from another bike and took for a ride. Got 2Km from home and it stopped and was unable to get it started again, so had to push home (down hill). After checking the easy stuff (plug, etc) it turns out the electronic box has died. Was hoping not to have to spend any more on this one.