'69 TS250 Restoration

Also the DS250.

'69 TS250 Restoration

New postby apex on Sat Jun 06, 2015 11:34 pm

I joined this forum recently, as I'm finally, after 4+ years, assembling my '69 TS250 restoration project, and found the need to ask some questions. Glad I found the forum!!! I found this TS250 on eBay in Minnesota, won the auction and had it shipped to me in California. What you see if how I got it: missing cylinder and piston. But the head and pipe was there, which was nice, and tucked in the tool "box" so to speak under the seat was all the mounting hardware in a baggie. That was a nice touch! I bought this with the intent of doing a nut and bolt everything restoration, so essentially I got it, then took it completely apart. Here it is the day it was dropped off. I'll continue to post my progress when I have time, so I'll post this start to whet your appetites.

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Re: '69 TS250 Restoration

New postby apex on Sun Jun 07, 2015 1:06 am

Continuing to tear down.

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Car 6V coil. Whatever...

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Unobtainium headlight, ring and brackets were still there thankfully.

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Re: '69 TS250 Restoration

New postby apex on Sun Jun 07, 2015 1:09 am

Frame Tag went into a baggie for re-assembly.

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Cracked fender. The last TS250 I had was cracked too.

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Re: '69 TS250 Restoration

New postby apex on Sun Jun 07, 2015 1:14 am

All apart, parts are bagged and separated for whatever happens next.

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Bolts laid out a documented before heading to the Chrome & Zinc shop.

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More. Chrome is RIDICULOUSLY expensive!

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Parts for polish.

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Re: '69 TS250 Restoration

New postby apex on Sun Jun 07, 2015 1:22 am

Powdercoat done! This was about 3.5 years ago.

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And here's that same frame, about 3 months ago. In fact all photos from this point forward are within the past 3 months. I really sat on this project, and it even included a move from California to Idaho. I wanted to get everything done, before I assembled the bike, but came to the realization if I did wait, it might NEVER go together. So I've decided to put it together as-is, and finish the stuff that needs finishing as time goes by. I just don't have the budget for another $1000 in chromework!

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This is all the Zinc, some of the part that were polished.

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Engine with polished side covers (done poorly, guy I got to do them was cheap, and you get what you pay for). The cylinder is NOS. Also NOS is the piston, pin, pin bearing, clips, and a NOS genuine Suzuki gasket kit. Sweet!!

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Hiding in the gray wrapping paper is the gas tank, $600 of green with silver striped goodness.

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Re: '69 TS250 Restoration

New postby apex on Sun Jun 07, 2015 1:32 am

Here's the engine, together,properly bolted up and the covers hit with polish. NOW it's coming together.

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Time to lace a wheel. When I originally took the bike apart 4 years ago, the bike sat in my driveway apart for 4 hours, as I had an errand to run. When I returned and started putting it all away, the rear wheel was GONE! I even had photographic proof it was resting behind the front wheel against one of the bushes in front of my house. That was the only piece taken. STRANGE!! I got a replacement back at that time off eBay, but the rear rim was severely pitted. The hub and spokes were OK, so I had the hub polished and the spokes re-done with everything else. The rim in these photos are yet another rear wheel I got from a wrecking yard, a much nicer rear rim.

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There's the back wheel that vanished. One of the strangest things...we lived in a very safe neighborhood that always had lots of activity, but way off the beaten track. Oh well...

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Here we are laced, and trued.

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Ready for the bike.

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Re: '69 TS250 Restoration

New postby catfoot on Sun Jun 07, 2015 4:42 am

Super job so far PLEASE keep us posted. Great pictures. Thanks for sharing.
When it quits leaking add oil
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Re: '69 TS250 Restoration

New postby DancesWithPoultry on Sun Jun 07, 2015 7:54 am

+1 to that.

Cheers

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Re: '69 TS250 Restoration

New postby LWC82PE on Sun Jun 07, 2015 8:49 am

If you prepare/repair/polish the parts to be chromed first by yourself, it will be cheaper. Much of the cost is in the preparation so if you do that yourself it is less hands on labor work done by the chromer and you should save some money.
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Re: '69 TS250 Restoration

New postby stacker on Sun Jun 07, 2015 9:12 am

Nice job mate. Keep the progress updated.
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Re: '69 TS250 Restoration

New postby kingclassic on Sun Jun 07, 2015 10:10 am

Both wheels were placed near the plants?Only one missing?and that seems close to the sidewalk?Hmmm......why the bugger didn't take both?

That is STRANGE! ;)


Hilmi from Malaysia.
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Re: '69 TS250 Restoration

New postby kingclassic on Sun Jun 07, 2015 10:36 am

I think the guy who steals your back wheel has got a bike build off project?

Hilmi from Malaysia.
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Re: '69 TS250 Restoration

New postby apex on Sun Jun 07, 2015 8:58 pm

kingclassic wrote:I think the guy who steals your back wheel has got a bike build off project?

Hilmi from Malaysia.


Yeah whoever took the wheel had to move the front wheel to take the back wheel. VERY strange, we had some other things vanish only to turn up years later at that house, found in places where they things had no business being found. Either someone was messing with me, or we had a devious ghost. I choose ghost.
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Re: '69 TS250 Restoration

New postby apex on Mon Jun 08, 2015 8:19 am

Engine done, then time to put it in the frame. Used a sanding disc to grind off the powdercoat to make room for the engine on the frame flanges, and for good grounding. Engine is in! And fitted the tank as I paid good coin to have the paint done right, and needed to see where my money went.

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When I took in the two axle bolts and swingarm bolts as part of all the chrome, the chromer did the entire bolt, including the shafts. For axle bolts, that meant they were now too fat to pass through the wheel bearings, and the swingarm bolt was now to fat for the bushings. I found a machine shop to turn the new chrome off the bolts to get them back to the original size. Just adding costs, and live and learn. Once the bolts were done, it was time to unwrap the swingarm (it had been wrapped 3 years!), clean up the side washers, grind the powdercoat off the frame, and install the swingarm. Add new shocks, and it sure looks good.

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Re: '69 TS250 Restoration

New postby kingclassic on Mon Jun 08, 2015 8:30 am

Keep coming!keep coming! :)

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