The GuN - 1993 Suzuki GN250 Tracker

lior_baruch

lior_baruch

Been Around the Block
DTT BOTM WINNER
Hi all,

Just got myself a 1993 Suzuki GN250 with 25K miles (about 40K KM), in a very original condition.

Boring 8)

I'm going to make some kind of a tracker out of it...

That's how I bought it:

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Re: 1993 Suzuki GN250 Tracker

Instead of the original 315mm rear shocks, I ordered 365mm that will straight the way it looks.. there's going to be a problem with the rear brake lever, as well as the muffler bracket, I'll get to that when I'll get the shocks.


Front End is out, in order to replace oil seals and to replace the dust covers with more appropriate ones:
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Exasust wrap... just because... :)
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Ducati Darmah's front fender will do the work as the new rear one, it's made of Stainless steel so I'll polish it once ready
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Current seat - out... needs to be replaced with a flat one
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Leftovers..
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The fuel tank angle should be aligned with the frame, so I used spacers for that in order to get rid of the 'custom' look
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The triangle should be cleaned... meaning, no battery (small anti-gravity once will replace the old one in a different location, TBD)
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starting to work on the new seat base
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alignments
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Starting to look as I wish it would look...
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Front fender chopped a little... or more than a little... :)
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I replaced the muffler with a chopped one of a Ducati 900SSD, the sound it makes now is ^%@5&* amazing!
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Re: 1993 Suzuki GN250 Tracker

The making of the seat base:

Cardboard is being used to get the exact shape, folder to two, for best accuracy
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1.5mm sheet metal
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Done
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Bending the sheet metal like the frame's curves
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Cardboard brackets
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Brackets
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Using a special tool to press the sheet metal with the required shape/depth
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Welding the bolts
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Ready for some leather... :) I'm waiting for few grips I bought at Dime City, to see which will fit.. and than to choose a cover color that will suit the grips.
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Between the seat base and the bracket on the frame I'll use 8-10mm rubber washer
 
Re: 1993 Suzuki GN250 Tracker

Next steps....

Lowering the front-end

Seat cover

Replacement of headlight

Canceling the side covers and 'cleaning' everything inside...

Tracker handlebar

New tires, maybe 25% offroad

Maybe... changing the rear wheel to 17" from a DR650

New tail light

Blinkers

And more.. and more... stay tuned... feel free to ask anything :)

Lior.
 
Re: 1993 Suzuki GN250 Tracker

Cool! looking like it'll be great :) I'm working on a '93 GN250 at the moment too, will be interesting to follow your build!
 
LOoking good man!

You shouldnt have a problem since you are fitting longer shocks, but make sure to bottom them all the way out when you pout them on and make sure your wheel doesnt contact those seat brackets, they are pretty low.
 
SONICJK said:
LOoking good man!

You shouldnt have a problem since you are fitting longer shocks, but make sure to bottom them all the way out when you pout them on and make sure your wheel doesnt contact those seat brackets, they are pretty low.
Click to expand...

Thanks :)

As the new shocks will raise the bike, I don't expect contact with the brackets. If there will be any, I'll handle it ;)
 
Thats what I'm thinking as well, but always better to check than slam your tire into the frame at 50 mph when you hit a bump ;D
 
Work continues...

Turn signals bracket

Aluminum base
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Cut & Drill
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Rear fender is actually a front Ducati Darmah's fender... mounted, with a rear light
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New tracker handlebar. Ignition switch is lowered to lower the general look of... everything...
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Using the original gauge bracket for a single speedo bracket (temporary, as I'll use one from DCC with warning lights etc. once I'll get it)
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Brake pedal had to be modified, as the rear arm was touching it when I lowered it (to fit with the 50mm longer springs)
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After
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Almost clean... ;)
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Done for today 8)

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That will be the height of the bike with the new springs
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HELP...... what do you think about this yellow as a color for the fuel tank as well?... :)
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Just stumbled into this today. I started my '80 GN400 cafe build not too long ago, so I'm excited to see your bike and the direction you take it. I probably look at your CB350 on a daily basis. It's an incredible build, so I'm sure this bike will be amazing as well. I'm not crazy about yellow, but it's not really a color that I'd choose for anything other than a schoolbus or taxi.
 
Progress... :)

The seat base was painted and foamed. Will be ready later this week.
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Fuel tank and front/rear fenders ready for painting. I choose an interesting color... with interesting scheme... will be ready within few days ;)
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New shocks arrived, note how high the bike is compared to original, the rear wheel touch the floor with the center stand 8)
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New battery
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There is a good chance that this mini-project will be done later this week :)

Lior.
 
New 5.5" headlight, instead of the 3243254324" original one of the GN :)
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All the connectors and harness that was hidden in the headlight was removed to be hidden under the fuel tank, while using the original connectors for easy maintenance.
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Done... but not completed :)

Took about a month... soon I'll change the gauge, make new rearset and few more.. it will be an ongoing project :)

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