Suzuki TS250 Rebuild

Saturday 21 June 2014

This will be a short post, as the engine, after its full rebuild, started straight away. Nice!

Posted by johnnewcombe at 02:49

Part 4 - Rewiring

When the bike was purchased, only the bare essentials had been wired using the blue and brown wires from some mains flex. Naturally, this...
Part 2 - The Engine Rebuild

We have separation. This was the first thing on the agenda. The engine had not been split before and after 35 years proved to be a tad t...
Part 6 - The Carburetor

After the success of a easy engine start the bike went for it's 'daytime' MOT and passed with flying colours. However, the sub...
Part 1 - The Purchase

Note the incorrect exhaust and re-engineered head. After a mad hour on eBay I found myself to be the proud owner of a 1979 Suzuki TS250....
Part 8 - The Battery Box

The battery box was not supplied with the bike when I purchased it and these are near impossible to obtain so I decided I would make one. Af...
Part 3 - Removing the Blind Bearing using a 'Lewis Bolt'

There is a blind bearing on one side for the gearbox shaft, this was a challenge to remove. Despite many discussions with experts on the S...
Part 9 - On the Road

Having spent so much effort getting the battery box sorted, I decided to miss a few steps and MOT the bike so that I could use it. The batte...
Part 7 - Silencing the Noise

Silencer with rivets drilled out. According to two of my neighbours, my TS250 is too noisy. To be honest they are probably right as ther...
Part 5 - Engine Start

This will be a short post, as the engine, after its full rebuild, started straight away. Nice!