making one bike from two
 

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.

Re: making one bike from two
 

Very nice colour of the other one!

Re: making one bike from two
 

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:

Re: making one bike from two
 

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

Re: making one bike from two
 

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) :)

Re: making one bike from two
 

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.

Re: making one bike from two
 

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! ;)

Re: making one bike from two
 

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.

Re: making one bike from two
 

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. :)

Re: making one bike from two
 

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

Re: making one bike from two
 

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

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 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

Re: making one bike from two
 

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. :)

Re: making one bike from two
 

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.

Re: making one bike from two
 

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 :).

Re: making one bike from two
 

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

Re: making one bike from two
 

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

Re: making one bike from two
 

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

Re: making one bike from two
 

Keep it up. This is going to be awesome.

Re: making one bike from two
 

Re: making one bike from two
 

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

Re: making one bike from two
 

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

Re: making one bike from two
 

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

Re: making one bike from two
 

@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?

Re: making one bike from two
 

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.


:)

Re: making one bike from two
 

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.

Re: making one bike from two
 

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

Re: making one bike from two
 

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

Re: making one bike from two
 

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

Re: making one bike from two
 

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.

Re: making one bike from two
 

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:

Re: making one bike from two
 

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)

Re: making one bike from two
 

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.

Re: making one bike from two
 

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).

Re: making one bike from two
 

Bought in UK recently

Re: making one bike from two
 

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.

Re: making one bike from two
 

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

Re: making one bike from two
 

Nice! hope the carb problem will be fixed soon!

Re: making one bike from two
 

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

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

Re: making one bike from two
 

Waw! And it fits to GZ?

Re: making one bike from two
 

Looks like it will work well and you can't complain about the price. A double win in my books.