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Joe, that makes sense. Another issue that people encounter on old bikes is a dirty supply line - in other words, the voltage ripples and fluctuates. It needs a good sized battery, modern rectifier and regulator and a decent alternator. Do Powerdynamo offer an ignition/alternator setup for that bike?
Well shit, look what I found: http://www.powerdynamo.biz/eng/systems/7261/7261main.htm Full electronic ignition with a 180watt output, or a little over 12 amps. That is enough to charge the whole efi system and with the electronic ignition the tach issue shouldn't be a problem....I'll need to think about this one. It'll be another $400 plus shipping, but considering I've spent over a grand on the efi system...I'll sleep on it and start saving my pennies. I've got the headlight rubber cushions in and got the headlight installed. Fairing and seat have primer on and are taking shape.
I got the fairing painted and the new dash made up.
I tried out a couple designs for the layout and found something I liked.
Design chosen and cut out of 16 gauge steel:
Initial layout:
Powdercoated with everything installed:
I'm looking at my options and I'll have a few side jobs in the next few weeks that'll pay for the ignition. I think I'll plan on purchasing and installing the new ignition when the engine is going back in the bike so I don't need to wire it twice. I'll be moving onto the seat
I was able to order the ignition system and should be expecting that in 2 weeks. I figured out the rough placement of the battery, relays, and efi controller. With this setup, all of the wiring will be hidden. I also picked up braided covering for the wires. The fuel pump is mounted. I'll paint the pump black to let it blend in with the oil tank. I'll be cleaning the cases and putting it together dry to test fit the exhaust pipes and various components.
I blasted and powdercoated the fuel rail and the aluminum adapter blocks on the throttlebodies.
Love that guage setup as well. The EFI is gonna be sweet when you are finished with it. What fairing is that? I keep bouncing back and forth between the flyscreen (if I can find one I like), and the fairing type you have (1/4 fairing?).
There's a universal 1/4 fairing on ebay for $60-$80 that has some of the same features as this one: http://www.ebay.com/itm/RETRO-CAFE-RACER-STYLE-HANDLEBAR-FAIRING-SCREEN-UNIVERSAL-FIT-7-HEADLIGHT-/320963826527?pt=UK_Motorcycle_Parts&hash=item4abaef535f .
However, I decided to go with the airtech streamlining ajsm4k dunstall fairing for $200:
http://www.airtech-streamlining.com/vintage/Dunstall.htm .
It has smoother lines and is very nice hand layed fiberglass construction. It turns out the ignition only took a couple days to be shipped here. I received it yesterday and everything looks to be in order. I'll use my old crank and put the engine together to test the ignition and modify the exhaust for proper chain clearance.
Thanks for the compliments. I've included a few pics of the new ignition. I'll need to wait till I get the crank back to do some electrical work. I got the exhaust mounted so I can do some reconstructive work on the chain side. I mounted the throttle bodies and filters to get a look at the final product.
I was able to get the center bearing to finish off the crank rebuild. Hopefully I'll be seeing the crank in 3 weeks or less so I can get to pressure testing the bottom end. What I can do in the meantime is start on the wiring. I made up a steel enclosure for the battery, hei module, microsquirt, relays, and intake air temp sensor. I also included a crappy ms paint of what the bike will look like in gold. I decided to paint the seat gold as well instead of semigloss black. I'll be getting in touch with a guy that can sew up a good looking seat as well. All in all everything is going well.
I was able to get all of the wiring done for the computer. Ive still got the dash to do but that is quite simple.
I also experimented with some pexiglass. I formed it on the original metal alternator cover plate. With a little more work and maybe a slight tint I think it'll work.
I also took an extra clutch cover and milled off the suzuki logo. I then sanded and polished so it looks like it was never there.
I think I'll pull the crankcase again and install the bad crank so I can mount the crank sensor along with more wiring.
I popped the crankcase out and thought about powdercoating the case black. I decided to do just the upper half. There are only a few angles where the lower case can be seen and there is about double the work to get it done. So I ended up with this:
I can powder coat the oil pump cover as well. I hope this look will make the polished covers pop and give the engine a freshening up instead of the oxidized aluminum look. One thing I found out this time around is the use of high temp masking tape. I had taped off all of the machined sides and openings of course, but also to not get any powder on the inside of the case as well. I usually pull off the masking tape before putting it in the oven. I could only imagine what the tape would do at 400 degrees. I peeled off the sides, but I had to leave the ones on top, or else the powder would fall onto the rest of the part, giving it little dimples and bumps. So I threw it in the oven and hoped for the best. Well, it turns out it doesn't do much of anything. I had the case in the oven for over 35 minutes and when it was done, the tape peeled off just fine. Only a slight tackiness that can be removed with some lacquer thinner. No burning, charring or anything. Just normal blue painters tape. I had a slight setback on the center bearing I ordered. They mis-matched shipping labels so I need to ship out the wrong bearing and hopefully get the correct one from the other disgruntled buyer. I'm not in a hurry but I'd like to get my crank back asap so I can get to other things.
I got the cases bolted together with the crank so I can play with sensor placement. I also powdercoated the oil pump and oil line covers. I threw the clutch and alternator covers on to get an overall look. I still have to get the covers to a good polish but that will be later. Overall I like the contrast.
The clear generator cover was on my list of things to do so I'm stoked to see how well it worked out for you. I wasnt sure how i would accomplish it. Is there any chance you would be making more of those?
It worked out quite well. The initial one is good enough to use, but I think I can refine it more. I'm going to sandblast the "mold" and fill in the suzuki logo along with sanding it all smooth. Any little pit puts a small mark on the pexiglass. However, it is very simple to mold over. If you give it too much heat too soon, it'll start bubbling up within seconds. I think I've got enough to do a couple more. If not, its only a few bucks in materials. When I get around to it I'll make an extra one and send it your way. I've been busy working on other projects but this is still going to be done by spring.
Have been watching this thread for long time and love it!! what color of gold are you going to use, are you going with the factory color? with all the black you have the factory color looks sweet. not sure if they used it on the GT250, here is the color on my 550. great work by the way!!
I think I'm going with a candy gold, very similar to original color on the 75 gt250. Unfortunetly I've been so busy with my new car that I haven't touched the bike. I'm very close to having the crankshaft done though. I sent the crank guy new connecting rods a few days ago to finish the build. Overall I'll have about $600 into the rebuild including all three crankshaft bearings, all new seals, upper and lower connecting rod bearings, pins, and seals, and connecting rods. I"m looking forward to having the engine together and pressure test with flying colors. Thanks, Joe
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