Suzuki Intruder (GN) 250cc from Brazil

Montag

New Member
Hey guys!

My name is Luiz and I'm a 24 yo lawyer from Brazil.

I've been lurking DTT for a long time and finally have my own bike to start a build. :D

It's a 99/99 Suzuki Intruder 250cc. Worldwide you may know it as GN 250 but here Suzuki just gave it this name.
Anyway, the bike is not that bad. The brakes are trashed. Forks are leaking. But it runs good, except for an electrical issue.

As soon as I finish my mechanical course I'll tear it apart and rebuild it from zero. I wanna make sure it's flawless.

My plan is to make a cafe racer. I'm aware of the geometrics of the frame and the problems it gives me, but I have some ways to deal with it. Let's see in the future.

This is the bike:





Some of my inspirations are these bikes:




That's it for now. I'll keep you updated!
 

Montag

New Member
Re: 99/99 Suzuki Intruder (GN) 250cc from Brazil

Good progress today! Got the bike stripped down. Like I said, it was a mess. Check the wiring:



But the good news is the frame geometry is way better than I expected. Lowered the forks 4cm just to get the stance I'm looking for. Maybe I'll go lower by cutting the springs.





Now I'll clean the carb and build a mock seat to see where to cut, bend etc.
 

Montag

New Member
Re: 99/99 Suzuki Intruder (GN) 250cc from Brazil

These images show how the seat pan will look like.

The size is pretty much spot on although I think I'll make it narrower.





I orderer some parts and today I lowered the rear shocks to get a lower stance. Looked way cooler!

This saturday I'll reap the rest of the bike and cut off what is not necessary. The rear also!
 

Montag

New Member
Re: 99/99 Suzuki Intruder (GN) 250cc from Brazil

Good progress today!

Cut the frame:


Made a pipe:


Front and rear mudguards:


And took everything apart:
 

Math750

New Member
Re: 99/99 Suzuki Intruder (GN) 250cc from Brazil

To acompanhando Luiz, belo projeto, acompanho faz um bom tempo o forum tambem mas ainda não tinha começado a minha, essa semana começei e ja tirei umas fotos em breve começo meu topico, uma CB 400! Good look, looking forward to seeing yours next steps!!
 

Montag

New Member
Re: 99/99 Suzuki Intruder (GN) 250cc from Brazil

Math750 said:
To acompanhando Luiz, belo projeto, acompanho faz um bom tempo o forum tambem mas ainda não tinha começado a minha, essa semana começei e ja tirei umas fotos em breve começo meu topico, uma CB 400! Good look, looking forward to seeing yours next steps!!
Valeu, irmão! Boa sorte!!
 

Montag

New Member
Re: 99/99 Suzuki Intruder (GN) 250cc from Brazil

Quick update: bought some stuff for the bike

Clip on handlebars: http://www.ebay.com/itm/251352021967?ssPageName=STRK%3AMEWNX%3AIT&_trksid=p3984.m1497.l2649

Mirrors: http://dx.com/p/universal-round-shape-aluminum-motorcycle-rearview-mirror-black-pair-162358

Turning signals: http://dx.com/p/10w-motorcycle-yellow-light-turn-signal-lamp-black-orange-12v-236015

Rear/brake light: http://www.ebay.com/itm/310758063526?ssPageName=STRK%3AMEWNX%3AIT&_trksid=p3984.m1497.l2649

Didn't finish the frame mods yet. Hope to get it done by the weekend so I can start to build the seat.
 

Montag

New Member
Re: 99/99 Suzuki Intruder (GN) 250cc from Brazil

Painted a lot of small parts. Mate black all the way! Although it's a spray can, the job isn't that bad.





This is how my speedo setup will look like:



Clean and minimal. Just the hodometer and the neutral light over the table.

Started to install the pipe thermotape but the 5m didn't even get to the half of it. Ordered 5m more.



Yesterday I disassembled the wheels and hubs. The frame isn't done yet!!!

This is my carb, a 34mm Mikuni. That's huuuge!

 

Montag

New Member
Re: 99/99 Suzuki Intruder (GN) 250cc from Brazil

The rear loop is done. Finally!

Now I can build the seat pan and so on.

There's also a bracket for the mudguard (that small piece you can see some posts ago).





 

Montag

New Member
Re: 99/99 Suzuki Intruder (GN) 250cc from Brazil

Finished seat pan:



I used a "Pare" (stop) plate. It's cheap and looks cool, kind of "fuck the police" feeling.
 

Montag

New Member
Re: 99/99 Suzuki Intruder (GN) 250cc from Brazil

Busy weekend. Did a lot of work.

The seat pan is almost done. The size feels right and the look is cool too. I need to choose what kind of foan I'll use and the seat design, for sure. Don't know if I go for a flat look or a duble decked one, following the frame curve.





Also made a paper mock up for the battery box. Great news btw: my 6ah battery is working just fine so I'll keep it anyway.



I'll try to draw some seat designs now.
 

Montag

New Member
Re: 99/99 Suzuki Intruder (GN) 250cc from Brazil

Wheels are done. They look cool.



Right now I'm trying to get a good stance on the seat.

 

ILoveThumpers

Everywhere is thumpers!
Re: 99/99 Suzuki Intruder (GN) 250cc from Brazil

I like the wheels. Stainless on black is slick.

I'll be interested to see what you're planning for the carb.

-Deek
 

Montag

New Member
The build is going just fine.

Good news: maybe the stock seat can become my custom seat. The foam will be trimmed in a slick, narrower form. I'll try my best to make it happen. Not my first choice but if I manage to get a good seat I'll use it anyway. That'd save me a few bucks for sure.



The forks are ready to be rebuild. Lowered also!

 

Montag

New Member
Pipe is done!! It's looking very badass.

10m of white thermotape did the job.





Yesterday I got the clip ons. They fit like a charm!
 

Montag

New Member
Great news, folks. The welding part is over! The battery box looks really really cool IMO.



It's big enough to store the battery, the ignition switch (pictured) and everything else. The regulator will be outside for sure (right panel).



Orders coming from all over the world. So much joy!



I started to draw my new wiring. Very clean and small.
 

Montag

New Member
Worked on the seat today.

I glued the original foam on the metal plate and then shaped it.

Not bad IMO.







Some steps:

 

Montag

New Member
The gas tank is done.

Looks like a giant viagra! LOL

I liked it anyway.



The seat will be done next week. Dark brown leather was the choice. Let's see!
 

Montag

New Member
Currently working on the frame paint.

First I sanded it all. Then 2 layers of primer. And some more sanding. After that came the black. Now I need to varnish it.





My seat will be done by friday. Can't wait!

PS: true garage build over here. no doubt!
 

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