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Author Topic: Ton up SR250 - a cafe racer by the numbers: 100mph, 100kg, 30hp  (Read 45764 times)

Offline Jimbonaut

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Re: Ton up SR250 - a cafe racer by the numbers: 100mph, 100kg, 30hp
« Reply #360 on: Aug 01, 2019, 10:37:53 »
Wish I knew about that thing when I hammered out the dent in my cb tank.  Man that worked a charm, nicely done
"I'm telling you Donnie, nuthin' but nuthin' but right"

Offline Rider52

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Re: Ton up SR250 - a cafe racer by the numbers: 100mph, 100kg, 30hp
« Reply #361 on: Aug 01, 2019, 15:37:48 »
Nice job on pulling the dent. I've seen those tools, but never used one.
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Offline wozza

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Re: Ton up SR250 - a cafe racer by the numbers: 100mph, 100kg, 30hp
« Reply #362 on: Aug 01, 2019, 21:02:36 »
I
The hardest thing was getting the hot melt glue off afterwards without damaging the paint.  I used a plastic 'spudger' from Ifixit (from my Mac repairing days).  It was brilliant - a hard and stiff enough plastic that you can scrape with, but soft enough not to gouge the paint.
isopropyl alcohol will help with clean up and removal....Your lucky(or more skilful ;) )  as the few tanks I tried on failed due to the thickness of the metal and the small size of the dents....

Offline Rat_ranger

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Re: Ton up SR250 - a cafe racer by the numbers: 100mph, 100kg, 30hp
« Reply #363 on: Aug 02, 2019, 02:50:33 »
I had some large shallow dents in my dt400 tank.  I used a tool just like that from harbor freight.  It did a surprisingly good job.  It did take some paint and decals off, but I was stripping it anyway.

Offline zap2504

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Re: Ton up SR250 - a cafe racer by the numbers: 100mph, 100kg, 30hp
« Reply #364 on: Aug 02, 2019, 18:10:58 »
I originally had one of those "bridge" pullers too. Saw the video results of the "slide hammer" tool and got one of those instead (why I recommended it a while back). Better control over force applied, not limited to what structure the "bridge" rests on, etc.
Yes, a plastic body putty spreading tool can also be used (with rubbing/isopropyl alcohol) to remove dried glue. In the video I saw they used a plastic "razor blade" with great effect too.

Offline pidjones

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Re: Ton up SR250 - a cafe racer by the numbers: 100mph, 100kg, 30hp
« Reply #365 on: Aug 02, 2019, 18:39:43 »
I bought some of the plastic razor blades from West Marine. They are used for removing stickers, labels, stripes, etc.
"Love 'em all.... Let God sort 'em out!"

Offline JadusMotorcycleParts

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Re: Ton up SR250 - a cafe racer by the numbers: 100mph, 100kg, 30hp
« Reply #366 on: Aug 04, 2019, 10:44:06 »
Gotta get me some plastic razor blades then!  Genius!

Zap the slide hammer was in another price category but I understand the use and it would come in handy for future projects no doubt. 

Offline doc_rot

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Re: Ton up SR250 - a cafe racer by the numbers: 100mph, 100kg, 30hp
« Reply #367 on: Aug 05, 2019, 02:57:22 »
Majority of sport bike axles are much larger diameter. I'm guessing the SR250 has 17mm front axle and 20mm rear? Could probably find a swing arm pivot bolt to fit but it would need cutting and threading. I think Suzuki used 17mm 'gun drilled' on early GSX-R? Not too familiar with other brands so couldn't make a recommendation

Yeah GSXR750  20mm rear 17 or 15mm  front depending on year. Easily adaptable. cheap. The factory axles are swaged where the threads are so they are extra thin and light and use a smaller nut.

Just out of curiosity how much was it to EDM those axles?
« Last Edit: Aug 05, 2019, 02:59:02 by doc_rot »

Offline JadusMotorcycleParts

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Re: Ton up SR250 - a cafe racer by the numbers: 100mph, 100kg, 30hp
« Reply #368 on: Aug 09, 2019, 03:39:02 »
It cost an arm and a leg!  50 and 60 Euro respectively.  To have custom ones machined would have been much more and to modify something else would also have cost a bit - considering I would not have been able to do the work myself.

Offline JadusMotorcycleParts

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Re: Ton up SR250 - a cafe racer by the numbers: 100mph, 100kg, 30hp
« Reply #369 on: Aug 09, 2019, 03:50:58 »
Found some time this week to start rebuilding the forks!  Geeze these ones were shot.  I was not expecting to need to order new holding clips (completely rusted out).  New seals and dust seals I already have.  These, along with the fork emulators, new oil, trimmed springs and the pre-load adjusters I have designed will get installed.  The fork legs will also get shaved - to remove the fender mount brackets (will mount the fender on the fork brace) and blasted.  The seals were stubborn as hell to get out but with force and heat they came.

Of course I weighed them too - for a before and after.  I presume there will be at lease a 100g weight reduction each side here too.

The stanchions have a bit of pitting in them, but it is nowhere near the working/sealing surfaces.  So I will polish them up and fill them with epoxy.  But the most important thing is they were both straight!  And the hard chrome surface down by the damper rods was also ok.