My first bike project!

[Kruse08]

I thought I would start a build thread to show everyone what I have done and ask questions along the way. I gave some history about myself within the new person section and posted some pictures. I have never worked on a bike before but have worked on cars. Much of the items are intimidating, (carbs, adjusting valves, etc..) since I am new to this world I am taking my time. I am not sure of the look I am going for other then a naked/cafe 250. I am not planning on tracking the bike as my rider skill level is low. I know that would be a great place to teach myself but money is tight with paying back student loans. I bought the bike about 3 months ago or so and have ridden a lot since then. I did a some maintenance when I got it but my friends dad who I bought it off of said it was ready to go. It runs well and everything but I should have checked the bike over like I always do with used cars.















As you can see in the last 3 pictures there are some trouble spots that need addressed. Surface rust on the swing arm and pitting/oxidation on engine covers and coolant lines. All of this will be taken care over time.

The first thing I did was buy a new windscreen as the original was cracked and sun damaged. I then decided to do a fender delete with some home depot items. It was simple and easy. Not much else really happened to the bike for a month or two. I just rode a lot and started getting the basics down. I am still needing to take the basic riders course but my work schedule has not worked out yet so I am waiting until mid July to do that.

Since I am a person who can not leave things alone and have an itch to tinker I decided that the rear suspension needed serviced. I bought a new gen shock with low miles, Soupys dog bones, and services the Uni-track while I had it off.



It feels much more controlled and has a better turn in while cornering. I also raised the rear say 1/2in to 3/4s of an inch. I feel more comfortable on the bike and do not feel like it so small.

As of yesterday 07/08/2014 I decided to dive into the bike and start making it a naked/cafe bike because I got an itch. I also thought it was time to do maintenance and check over some things. I have done a lot of research and looked at a lot of different naked/cafe 250s so I have some direction. Here is the bike sitting in the garage after tear down.





This is how I left the bike after I stopped for the night. Need to order some parts and go to work.

I decided I should check the air filter since I was unsure of when it was done and I found a bitter sore sight. This is what I found upon inspection.



The filter was oiled but it crumbled upon touching it, It is all over the inside screen of the air box and I am unaware of whether this would get into the carbs. The bike runs fine but now I am nervous. Has anyone ever seen an air filter do this?

[CZroe]

The filter element did that in one of the classic model parts bikes I bought. A pre-oiled factory replacement for my 2008 bike was in stock and only $10 when I bought one a few years ago. An aftermarket filter should work just as well though. Don't know how it may have affected the carbs to have that stuff contaminating (it obviously isn't fuel-soluable!) but I'd clean as much as possible from the airbox, replace, and drive if you haven't noticed any problems.

[Kruse08]

Yeah that is what I was thinking of doing since I have never messed with carbs before. I went ahead and bought a replacement filter from partzilla so I could fix the issue. I am hoping that cleaning all the stuff out of the airbox and replacing will fix everything as the bike runs fine.

[LNasty]

[Kruse08]

Originally Posted by LNasty

I take it you are in for a show?

[LNasty]

Originally Posted by Kruse08

I take it you are in for a show?

Indeed, love the build threads. Wish I had the time and money, as well as the space, to do one myself

[Kruse08]

Yeah it will be slow going as I still want to ride the bike and I still am needing to acquire a front stand so I can get the front wheel up and off the ground. A friend of mine gave me a rear stand which has come in handy. Any advice or any questions are more then welcome as this is a learning process for me and I know a lot of you guys have been around for a long time.

[LNasty]

This is the best site for it. Came on here as a complete noob and have received a lot of help from members. Can't wait to see the progress.

[CZroe]

Until you get a proper front stand, parking the bike under a ladder and lifting with ratchet straps (through the frame/hole in front of the tank) works very well with the rear secured on a stand.

[Kruse08]

Well thanks for that idea though I do not own a ladder so I bet a front stand will be just as much. Great idea.

[Alex]

@Kruse08 - You're using too many IMG tags; I removed the extra ones from your post. When pasting in links from photobucket that already have the IMG tag embedded in them, you can just paste the link directly; you don't need to wrap them in additional IMG tags.

[Kruse08]

Thanks Alex, I will make sure to only past the link and not the IMG tag.

[Alex]

No worries! Just wanted to mention in case you were wondering why those extra tags were still showing up as text in your post.

[Kruse08]

A little update is in order. I have purchased a good amount of items so I can finish up the bike. Ordered a gs550 headlight/bucket from ebay, headlight brackets, 4x turn signals from ebay, a crg 2in mirror, and a new tailight (which needs to be ordered). I have also ordered a tinted visor for my headlight and an osprey raptor 14 hydration backpack. A new air filter is also on the way and I hope to have this all together in a week or so when I get the parts. I also think I am going to use a bike pedometer for my speedometer until I can order up a vapor. Hopefully this all works out.

[Kruse08]

Made some more progress on the bike over the past few days. Made some brackets and started getting the electronics placed in new areas. I am pretty happy with the results as I am no professional at fabricating. Had some old license plates laying around so one of those got used and then I bought some sheet metal. Used my dremel and went to town. Just waiting on parts still. The bike has a lot of work left but some things wont happen until next year.

[Kruse08]

Just another small update: Got a bunch of parts in over the last weekend and was able to get some more work done. Really should have waited to do all this until I had everything so I could keep riding. Installed new air filter, put on new headlamp with brackets, installed new mirror and did a little odds and ends here and there. I also purchased a tinted visor for my helmet. Still waiting on the turn signals and tail light to come in and about to order a trail tech vapor.

[c-dog]

Nice work! Cool project.

It's the Thigh-Master 2000! Suzanne Somers rocked it.

[Kruse08]

Thigh master? You have confused me and thanks for the kind words.

[c-dog]

The crazy thigh workout device you have hanging in your garage. Red thing circled in red. It's an old school work out device that Suzanne Somers pitched. It's to work out your thighs. Called the Thigh Master. I just got a kick out of seeing it in your garage.

Great job on the bike. It looks clean. Those Pre-Gens look awesome stripped down and modified.

[Kruse08]

Haha, wow that went over my head. Never thought anyone would comment on an item they saw hanging in my garage. Glad I could be of service for your enjoyment.

[choneofakind]

What are you doing with the spare plastics?! They match mine

Also for lifting the front the ghetto way. Take a 3x3x1.5 block of wood. Drill a 1.5" (or so) hole that's about an inch deep to clear the oil filter bolt. Use the block of wood under the oil filter bolt as a jack point for a cheap automotive succor jack. Done. Be careful though, it's not the most sturdy

[Kruse08]

I am not sure of what I am doing with the plastics yet. I may sell them because my bike is most likely never going back to stock again. You are more then welcome to come look at them if you would like. Yeah I am still trying to find ways of getting the front wheel up, I may go buy a front stand so it is more sturdy. Thanks for the idea.

[c-dog]

Originally Posted by Kruse08

Haha, wow that went over my head. Never thought anyone would comment on an item they saw hanging in my garage. Glad I could be of service for your enjoyment.

Totally no disrespect man. Just saw it and forgot about them. It's always interesting seeing what shows up in the background of pics people post. Hopefully I didn't offend you just having a little fun.

[Kruse08]

Not at all, I enjoy giving free laughs. I do not want to see this thread empty. It does not have to be all talk about just the bike project I am working on.

[Kruse08]

I thought I would update everyone and let you all know that the bike is now street legal and back on the road after four weeks. Everything works properly and I am in love with the way the bike is now. I will post pictures later on today.

[c-dog]

Excellent. Post pics when you get a chance. Hope you are having good weather this weekend so you can get some rides in on your finished bike.

[Kruse08]

Here are the most recent pictures. I was able to go on a small 30 minute ride yesterday to test out the bike. I love the feel of no fairings and the nimbleness the bike has now. I also really like the Trail Tech Vapor gauge as it really updates the bike. I have a lot more work to do yet but the first stage has been completed with my own hands in my own garage. Happy to have tackled this myself.





I found this to be the most cost effective way to mount the speedo. It cost me about 2$ and 5 minutes time cutting down the l-bracket.

[PF1]

The bike looks awesome man. It's close to what I want my bike (when I buy it) to look like.

[Kruse08]

Thanks, it is not close to being finished. Just in the beginning stages. Ask any questions about what I did and I am more then happy to help.

[KawiKid860]

Looks kind of like my 500! Mine still has the rear plastics though, dunno if I'll ditch those or not.

[Kruse08]

Yes it does kind of look like yours but more naked. I thought I would update a little. I am a huge fan of the way the bike feels now. Do not know how to describe it but it just feels better. I am going to be installing Venhill SS brake lines this weekend, front and rear. I also may be putting on the superbrace I got. I am also in the works of tracking down a new set of forks so I can rebuild them for my winter tear down. A new swingarm will be tracked down as well and also rebuilt. I am hoping that in the spring the bike looks like new and is not so ratty.

[ninjakuma]

Awesome bike! Inspiring.

Do you plan on painting the coolant tank or leaving it that god awful cream color? IMO that's the thing that sticks out most when I have my bike stripped down, that and the wiring on the other side.

[Kruse08]

I am actually in the works on finding a different bottle/container that I can use. I dislike the stock one as it is ugly so I have been doing research and seeing what others have done. The bike will most likely never be sold as I really like the 250. I think it is a great bike to have around no matter what other sized bikes you have. So with that said it is a work in progress.

[jkv45]

Originally Posted by ninjakuma

Awesome bike! Inspiring.

Do you plan on painting the coolant tank or leaving it that god awful cream color? IMO that's the thing that sticks out most when I have my bike stripped down, that and the wiring on the other side.

One thing you can do is to put a piece of 1/2" or 3/4" tape vertical on the overflow tank to show the level, then hit it with some black paint like "Fusion" designed to stick to plastic. Be sure to clean it real well first.

That way it would all but disappear.

[Kruse08]

Thanks for the idea though I think I may do a flask or possibly some sort of glass bottle attached to the radiator area.

[PF1]

I was wondering if anyone could tell me who made this bike? I saw it on Google it stated it was posted from this site but didn't give the persons name.

[Kruse08]

I do not know this bike but someone else may know.

[sumdawgtwigg]

I'm really considering doing this to my bike since the fairings have been painted very poorly by the previous owner. Great build! Very informative and inspiring.

[TBC]

Awesome job mate! Looks great.

[Kruse08]

Thanks everyone, bike is a long working project. So much to do and with me being newbto bikes it will take some time.