making one bike from two

[rynr]

Here are two bikes which are part doners.

The idea is to put 250cc engine into 125cc motorbike.

Not much done yet, first photo will release very soon.

[PimpS]

Very nice colour of the other one!

[rynr]

Some bikes from year 2001 has this colour, and i'm very proud to be an owner of 2001 GZ125 (it's original of course).

EDIT:
Just got back from garage - here's first photo:

[Water Warrior 2]

Welcome to the forum. Have to ask, did the 125 give up ? Both bikes look intact and rideable in the pics.

[rynr]

No, 125 went great - it just turned out to slow bike for me. I need something more powerful. Because of small amount of money i decided to buy a bike from insurance company (history of the bike unknown - propably not worth repairing after crash).

When i bought gz125 2 years ago almost every element needs restoration or replacement. So about year ago i did general restoration of this bike. If i would buy entire gz250 and sell gz125 i'd propably have to do restoration again - or pay too much money for gz250 in very good condition. So i decided to keep many good parts from 125 and just change the engine.

Anyway, it turned out that I bought entire bike in a price of engine with carboratour and exhaust.

Engine has only 14000 km, it hasn't been opened. Whole gz250 bike wasn't perfectly straight, but able to ride. There was only 1 problem - frame hasn't rights to registrate.

That's the story. I hope that it's possible to understand (not very good english) :)

[Water Warrior 2]

Now I understand. Sounds like a workable plan. The entire process may be time consuming but I'm sure you can do it. We will give you all the help we can and offer suggestions while letting you do the work. Looking forward to see the finished product.

[jonathan180iq]

This is going to be a fun project.
Please keep updating us with lots of photos and descriptions so we can all follow a long and share in your experience.

Nice work! ;)

[rynr]

As you see in picture with black one - aluminium side covers (maybe wrong name i use) are quite damaged. In places where painting got smashed there's serious aluminium corrosion. Today i'll show more photos of engine and tell solution i usually use to get it right.

[alantf]

As you see in picture with black one - aluminium side covers (maybe wrong name i use) are quite damaged. In places where painting got smashed there's serious aluminium corrosion. Today i'll show more photos of engine and tell solution i usually use to get it right.

Just one more reason to fit engine protectors/crash bars. I bet the rider didn't do his leg much good when the bike went down. :)

[CMS]

Here are two bikes which are part doners.

The idea is to put 250cc engine into 125cc motorbike.

Not much done yet, first photo will release very soon.

Really like the yellow color,I didn't know that color was used, and for a long time I didn't know they made a 125 version of the GZ, [US only gets the 250] learned about it here on the forum. They [Suzuki] seem to have different colors for different countries ,Canada has an all white model that looks very nice also. Here in the US I'v seen red ,blue, green,grey but mostly black colors. The TU250X has replaced the GZ in the US. Keep us posted on your project. CMS

[rynr]

As i heard, japanese producers give up on 125cc 250cc and selling licenses. Europe market is full of korean or china (the worst!) cheap bikes.

For example: http://www.mmt.com.pl/st/img/zipp_raven.jpg - body on suzuki license, engine on honda license.
Romet R250 or R150 - under the seat looks like gz :) http://moto.scoti.org/wp-content/upload ... 379962.jpg (http://moto.scoti.org/wp-content/uploads/2008/11/pb2379962.jpg)

Those chinesse ones are produced not very well, made from poor materials. Saving money on every part. Some parts are plastic instead of aluminium or steel.

http://allegro.pl/suzuki-gsxf-600-oraz- ... 58082.html (http://allegro.pl/suzuki-gsxf-600-oraz-marauder-gz-125-okazja-i2231858082.html) another in this colour, european 2001, they quite rare.
There's another great colour opposite red and orange (don't have photo right now)
New white GZ125 could be bought in Spain.

It's sad that american GZ doesn't have "marauder" logo on tank. GZs in Europe are called Marauders (Canada too?)

Edited: here are 3 another colors from 1999 http://www.bikepics.com/suzuki/gz125/99/pics.asp

[alantf]

Europe market is full of korean or china (the worst!) cheap bikes.



Those chinesse ones are produced not very well,

You don't have to tell ME!!!!!!! In 2005 I bought a Lanvertti (Chinese made) The engine was fine (Honda engine) but the rest of the bike had so many faults/problems that the local dealer got me my money back from the importers. That's when I got the Marauder. 20,000 kilometers down the line, no problems whatsoever. :)

[Water Warrior 2]

Yes, the Canadian GZ is called a Marauder. The large Marauder emblem on the tank is very nice and adds to the appearnce of the bike.

[rynr]

So here's the engine. Someone takled about engine guards - my engine wasn't damaged through an accident. Propably it stands on air for a long time (rain, snow, etc). That's because frame and engine painting on left bottom side is almost gone. Right side of engine is not so bad. Damages are only on surface, so i decided to polish it.

Solution:

to buy:
paint and varnish remover,
waterproof impermeable paper: granulation 320, 400, 500, 600, 800, 1000, 1200, 1500, 2000,
polishing paste for aluminium,
polishing paste (not waxing) for lacquer.

First thing is to remove varnish. Then I use paper 320, slide up and down (vertical) to get rid of corrosion of aluminium.
Next I use paper 400, but in left and right direction (horizontal) until scratches from 320 paper are gone. Then 500 up-down, 600 left-right...

On 1 of photos you can see chain cover after paper 1000 - now is in my girlfriend house - she'll do the polishing using first paste for alu, then for lacquer (second one is used to make surface more smooth than alu paste). Yesterday it looked like left side of engine :). I'll send image when it will be done.

That's a very time-absorbing solution, but only chrome will do better than this :).

[Water Warrior 2]

A lot of work but the results are very good. Your girlfriend sounds like a keeper.

[rynr]

Recently she became owner of GZ 125, so it just be couple items more to polishing (she's a polishing freak) :)

[rynr]

Some things done during Easter (in Poland we have two days off Sunday and Monday):

[jonathan180iq]

Keep it up. This is going to be awesome.

[CMS]

As i heard, japanese producers give up on 125cc 250cc and selling licenses. Europe market is full of korean or china (the worst!) cheap bikes.

For example: http://www.mmt.com.pl/st/img/zipp_raven.jpg - body on suzuki license, engine on honda license.
Romet R250 or R150 - under the seat looks like gz :) http://moto.scoti.org/wp-content/upload ... 379962.jpg (http://moto.scoti.org/wp-content/uploads/2008/11/pb2379962.jpg)

Those chinesse ones are produced not very well, made from poor materials. Saving money on every part. Some parts are plastic instead of aluminium or steel.

http://allegro.pl/suzuki-gsxf-600-oraz- ... 58082.html (http://allegro.pl/suzuki-gsxf-600-oraz-marauder-gz-125-okazja-i2231858082.html) another in this colour, european 2001, they quite rare.
There's another great colour opposite red and orange (don't have photo right now)
New white GZ125 could be bought in Spain.

Neat to see different colors. We [US] won't see the GZ here in future but I wonder if it will still be avalible in other countries? Still a reliable and good bike [as compared to the China junk] keep your posts coming thanks, Terry
It's sad that american GZ doesn't have "marauder" logo on tank. GZs in Europe are called Marauders (Canada too?)

Edited: here are 3 another colors from 1999 http://www.bikepics.com/suzuki/gz125/99/pics.asp

[rynr]

Some news, but no photos taken yet.

Engine is polished and mounted in frame.

Experienced some problems with the swinging arm. I had to use one from GZ125 because arm from 250 isn't perfectly straight. 125 engine has wider mounting place (pivot? wormhole?) where swinging arm shaft runs. Swinging arm has thinner pivots, so i decided tu fix a few washers on both sides to ensure correct arm position (front and rear sprockets must be parallel and in-line). It isn't professional mod but at least this will keep rear wheel just where it should be.

Photos soon

[Water Warrior 2]

You making progress and that can't be a bad thing. Post pics when you can.

[CMS]

You making progress and that can't be a bad thing. Post pics when you can.


RYNR, Read my post on side racks when you get a chance, let me know if they are avaliable, Thanks Terry

[rynr]

@terry

i'll answer in couple minutes


Bike is almost done - description and photos are made but not posted yet - all free time I spend in garage.

There's a serious problem with carb. It's very hard to turn on the engine. There's a spark on spark plug, engine is clean and everything else besides carb is in good condition.

Fuel comes through carb and floods spark plug as long as fuel valve (valve? on bottom of tank) is turned on - impossible to turn on the engine. After long time of starting engine is starts run but only for a while. I noticed that fuel comes higher than carb main fuel valve. I set the valve thght as much as I could, but it didn't solve the problem. Choke is not guilty - there's too much fuel even for choke.

Did the carb give up?

[mole2]

@terry

i'll answer in couple minutes


Bike is almost done - description and photos are made but not posted yet - all free time I spend in garage.

There's a serious problem with carb. It's very hard to turn on the engine. There's a spark on spark plug, engine is clean and everything else besides carb is in good condition.

Fuel comes through carb and floods spark plug as long as fuel valve (valve? on bottom of tank) is turned on - impossible to turn on the engine. After long time of starting engine is starts run but only for a while. I noticed that fuel comes higher than carb main fuel valve. I set the valve thght as much as I could, but it didn't solve the problem. Choke is not guilty - there's too much fuel even for choke.

Did the carb give up?

Sounds like you have a gummed up carb. You might have to pull it and clean it out. You could try an additive such as Seafoam or something similar to clean it but by the sound of it you should clean it manually. Sounds like the needle isn't seating so it floods.


:)

[rynr]

I left bike in my friend's garage. He works on motorcycles for many years and he knows stuff, so i hope he'll find a solution.

[PimpS]

I wish you all the best!!! Can't wait the pics!

[rynr]

here's couple of photos from 18.04 so quite old.

[PimpS]

Nice! Tyres are Metzelers? I think they are like mine... How do you like them!

[rynr]

yes, Metzeller me 77 - better than Dunlops. Bought last year. My girlfriend has 2008 Dunlops and they have cracks (perforation) already after four years. I've got somewhere 1999 Dunlops and they look better than made in 2008. We'll see how will Metzellers look like after coulpe years.

[Water Warrior 2]

Rynr, you have undoubtedly spent many hours of labor just cleaning. Few folks would have that much passion for a project and be willing to spend the time making things look as good as new.
Your 2 into 1 bike may inspire others to do the same thing in the future. :2tup: :2tup:

[rynr]

actually I don't recommend to do mix from GZ 125 and GZ 250 because there are many different parts (more than I though) and it's very time absorbing :) If anybody lives in country where you can earn serious money (definitely not Poland). It's better way to buy GZ 250 in good condition and eventualy put couple of better parts from 125 (for example tank and fenders if you like their color or sth)

[Water Warrior 2]

actually I don't recommend to do mix from GZ 125 and GZ 250 because there are many different parts (more than I though) and it's very time absorbing :) If anybody lives in country where you can earn serious money (definitely not Poland). It's better way to buy GZ 250 in good condition and eventualy put couple of better parts from 125 (for example tank and fenders if you like their color or sth)
Very true if the money is there. All the more reason to give you a big :2tup: for taking on a time consuming and labor intensive project. Your experience will also point out what is transferable between the 2 bikes.

[rynr]

Check out the gift from previous owner of GZ250 - turns out after draining the oil. Another one (good condition) already bought from GN250 engine (almost the same engine and exactly the same part - oil pump cover).

[rynr]

Bought in UK recently

[rynr]

OK bike is almost done. Carb problems haven't gone yet. I'm waiting for postage with carb rapair kit. Valve assy is damaged it's leaking. We'll see how it works with new valve.

[Water Warrior 2]

Looks pretty fine to my eyes. You did a lot of work to make this transformation work. :2tup: :2tup:

[PimpS]

Nice! hope the carb problem will be fixed soon!

[rynr]

I'm still waiting for the kit, those f*ckers from post office are doing nothing...

Also if it doesn't help, i'll buy another carb.

Today I bought engine guard originaly from chinesse Jinlun 250. Almost twice wider than dedicated for gz 250 and twice cheaper. Quality isn't the best but acceptable.

http://allegro.pl/gmole-oslony-silnika- ... 27302.html (http://allegro.pl/gmole-oslony-silnika-chrom-chopper-romet-250-i2332727302.html)

That's how it looks like, price is around 45-60$

[PimpS]

Waw! And it fits to GZ?

[Water Warrior 2]

I'm still waiting for the kit, those f*ckers from post office are doing nothing...

Also if it doesn't help, i'll buy another carb.

Today I bought engine guard originaly from chinesse Jinlun 250. Almost twice wider than dedicated for gz 250 and twice cheaper. Quality isn't the best but acceptable.

http://allegro.pl/gmole-oslony-silnika- ... 27302.html (http://allegro.pl/gmole-oslony-silnika-chrom-chopper-romet-250-i2332727302.html)

That's how it looks like, price is around 45-60$
Looks like it will work well and you can't complain about the price. A double win in my books.

[rynr]

summary (after 500 km (300 miles)):

With every kilometer it runs better (when GZ250 was bought there wasn't enough oil in engine - through accident GZ participate in - oil came to air filter when crashed bike was laying on side) - clutch, gearbox and "sound" are so much better than 500 km ago :)

Motul 300V is good oil. I recommend it for everyone. Mostly used in racing bikes and cars. Keeps engine clean.

Oil leaks from dust seal from left fork, but it's not a big deal. Seal replacing should stop leaking :)

Bike top speed and acceleration isn't worth comparing to 125. Transmittion has longer ratios. Bike runs faster than 125, driving is more delicate to acquire estabilished speed. No need to "juggle" transmition gears when accelerating or decerasing speed. I've got a feeling that 125 engine is to weak to provide comfortable driving on GZ bike.

But engine transplant - not worth doing :) Except many differences in parts, GZ125 frame isn't quite the same as in GZ250

[Water Warrior 2]

Does the 125 have the same number of teeth on both sprockets as the 250? Both bikes may have the same transmission but the 125 may have different sprockets to accommodate the smaller engine. That would make sense from a manufacturing cost factor.

[rynr]

Sprockets and chain are completly different. Both front sprockets have 15 teeth, but GZ125 has size 428 sprockets and chain and GZ250 has size 520 ones.

[5th_bike]

Seal replacing should stop leaking

There could be just some dirt between the seal and the stem, there was a post here today with it mentioned; here it is:


Here it is!! :cool: :)
http://www.youtube.com/watch?v=8wlzfoVroSY



PS your bike is beautiful, what a great job, please post a pic after the engine guard is mounted.

[rynr]

i'll try this, but my forks are 11 years old, maybe it's time to change the oil too and replace seal on the bottom before it starts leaking.

[CMS]

Bike looks great, Bravo !! Terry

[jonathan180iq]

i'll try this, but my forks are 11 years old, maybe it's time to change the oil too and replace seal on the bottom before it starts leaking.

You might as well, since you are diving right into everything else.
Keep up the excellent work and keep posting pictorial updates of your progress. This could be immensely helpful to others in the future.

[rynr]

I had an accident today, some idiot drove in front of me from minor road, from right side. Didn't have time or place to put motorbike to the ground (salvage) - just started handling. I'm quite okay - flipped on car mask and landed on legs. Bike needs new mudguard, little suspension straightening (loosing bolts put straight and tighten bolts) and at least headlamp ring...

Here are a few photos done before this, and 1 after.

[Water Warrior 2]

Very glad to hear you have no injuries from the mishap. The bike is repairable or replaceable if need be. I would imagine the crash bars saved a lot of damage when the bike finally can to rest.

[rynr]

Well, crashbar didn't help because i rided straight into the front-left side of car, my front wheel stoped in car's slot between it's wheel and fender. That's why my fender is in many pieces. The bike stopped in the car and was in standing position, didn't fell on the ground.

[Water Warrior 2]

That would certainly be a front fender killer for a bike. Do the forks still slide nice and smooth? They may be bent a little from the impact.

[rynr]

Forks are straight, but i've got 2 more from the black one in garage, maybe I'll use them :)

Anyway, a new fender has been sent :D

[Water Warrior 2]

Excellant. And it is the right color too.

[rynr]

i consider this (beacuse it may not be possible to buy another front fender): http://www.fehling.de/images/preise/ima ... 848dd9.jpg (http://www.fehling.de/images/preise/image07d555848dd9.jpg)

What do you think?

BTW. They produce many extras for various bikes and have positive opinions.

[Water Warrior 2]

Looks really nice but I doubt I would ever put a fender guard on a bike. I am a bit of a no bling kind of person.
In a minor crash the guard may save the fender. In a major crash the guard might add to the damage by transferring force into the forks themselves. Of course the front wheel itself will do the same thing.
In a major crash your own body will be of most concern and the bike is secondary or less. Spend the money on safety gear for your body. You are much harder to replace than a front end of a bike.

[CMS]

Rynr, glad you and your bike are ok, keep us posted on the repairs, I enjoy your pictures. Down the road if you ever run across any more of the side luggage racks let me know. Terry

[rynr]

Here comes lastest photo taken near vistula river.

[Water Warrior 2]

Rynr, you sure find some nice places to park the bike.

[CMS]

Rynr, have you found anymore of the side racks ? If so have the seller contact me or you can contact me here on the GZ250bike .com Thanks Terry [08 GZ] :2tup: