Geoff the giant small bike

[bogan]

Fun fact

A DR600 will fit in a GN frame.

I'll need to make mounts, but it's completely do-able.
Fits easy as pie (not the 3.1415926 thing)

Need Pics!

painted some more of the windows yesterday. they look sharp

They will be sharp if you press too hard with the paintbrush.

[ducatilover]

I'll get pics at some point today.

It looks like it's going to be...err interesting to mount, it looks like the lower part of the rear is going to hit the frame if I have the top rear mount with the swingarm like standard.
I'll have a bit of a play and see if I want to do it. (of course I do )

[ducatilover]

Poor lighting today
Here be some flat alloy dummy mounts for the lower front I bashed up, nice 'n rangi

You can see the lower rear mount with a bolt through it hitting the brake lever (used the bolt + ratchets to lift the engine in, I'm too weak)


This can be done if I have a two part rear mount.
If the rear mount goes from the top engine mount to the lower (down below the gear shift shaft) and then bolts to the original lower mount on the chassis (on the bar where the center stand mounts), then have one from the swing arm pivot that bolts to the other.
Hopefully the shit paint pic here helps visualise Incredibly shithouse paint image
Fits very well, I just have to trim the lower rear frame mount back and re-drill them and I can pull the motor back a bit more.

No issues with chain/frame clearance, but it'll need a roller on the swing arm as the sprocket is a lot lower than a GN one

Kind of neat that it'll only take 5 minutes with a hack saw to trim the mount and then start making some dummy mounts out of flat alloy poo I have floating around

The motor has the kick start blanked off and there's no electric start (bulge at the front is a second balance shaft, I think) I have all the bits here except the lever, so it looks like I'll have to open 'er up properly and install that.
It turns over rear nice, there's no play in the gudgeon, the piston is sweet, has new rings too, bore will want a hone as it's a bit ugly, but that's no big deal.
The head is very similar in design to a GN, but runs twin plugs.
The carb is okay externally, but I'll rebuild it once mounts are done
It even came with header pipes
There's about a million random spares, CDI, coils, gaskets, throttle tube etc etc

Oh and who loves my high tech Kiwi spec engine stand?

[Drew]

Cool.

Where you make plates to go from original mounts to your motor, you need to put a grommet/spacer/tube between the plates.

Also, you really really really wanna get the sprocket as close as possible to the swing arm mount. If you don't, the rear suspension won't rebound at all with the gas on.

[ducatilover]

Cool.

Where you make plates to go from original mounts to your motor, you need to put a grommet/spacer/tube between the plates.

Also, you really really really wanna get the sprocket as close as possible to the swing arm mount. If you don't, the rear suspension won't rebound at all with the gas on.

I'll be moving the motor back and up a bit when I trim the rear lower mount, so fingers crossed we don't have too many issues
Definitely have spacers between the mounts, don't want it to twist right out the frame

I like good advice

[ducatilover]

Motor is all in place, will get the front mounts machined up then take nice accurate measurements of the rear
I haz better idea for rear mount, so that's all happy.

I have to split teh cases by the looks of things, the kick start hole is blanked off and there's a box of kick start parts fucked if I'm roll starting it every time

Turns out the early DR650 is very similar internally, so I've got a pre-96 650 manual to use as reference

So, jobs to do,
Mounts.
Wiring
Zorst
Kick start
Hone bore
Skids


Oh, and work out the gearing and re-gear it to suit

[caseye]

So what? couple a daz"s maybe.
Pics all the way OK.
Looking good.

[ducatilover]

We'll have her sorted in a jiffy
No drinking = moar money for silly shit
I could probably buy another bike if I quit suckin' them fags too

[Fast Eddie]

I could probably buy another bike if I quit suckin' them fags too

that usually makes me money down here

[ducatilover]

that usually makes me money down here

Yeah, but you own a Honda

[tigertim20]

looking good man, NZ's only 600 Ginny 250?

[ducatilover]

looking good man, NZ's only 600 Ginny 250?

Chur, I hope it's the only one. Not many people are retarded enough to put bigger motors in such a shit frame.



It looks like I have to split the cases to install the kick start so I'll have to get inventive to get the clutch basket out

[Fast Eddie]

mm I like that..

dunno why more people don't buy gn250s and modify them. they are so cheap and parts are plentiful. perfect bike to chop up and make cool. Lots of bobber and chopper builds too.

the flat tracker be my fav so far that I have seen. coupled with a bigger motor would actually be a cool wee bike.

[MystikEagle]

Just read this whole thread and I must say that I think you may have changed my opinion of the GN250. Yours is looking pretty cool with the mods you've done to it! My dad is a mechanic (so I am a little mechanically minded also) so I think I may just keep my eyes peeled for something that needs some TLC, maybe even throw a new engine in or an expansion kit. At least I know who to ask if I need any pointers :P

[ducatilover]

dunno why more people don't buy gn250s and modify them. they are so cheap and parts are plentiful. perfect bike to chop up and make cool. Lots of bobber and chopper builds too.

the flat tracker be my fav so far that I have seen. coupled with a bigger motor would actually be a cool wee bike.

Damn that's pretty sweet!

Just read this whole thread and I must say that I think you may have changed my opinion of the GN250. Yours is looking pretty cool with the mods you've done to it! My dad is a mechanic (so I am a little mechanically minded also) so I think I may just keep my eyes peeled for something that needs some TLC, maybe even throw a new engine in or an expansion kit. At least I know who to ask if I need any pointers :P

Do it, it's very fun. You can get a 300cc kit cheap enough (I might even sell mine)
I'm more than happy to help out


Whipped the clutch out to get the blanking plate out of the kick start hole, everything inside this looks fresh, the bearings on the RHS look new, so that's a good start.

Made a clutch hub holder from a spare pressure plate, four bolts just like the 'zuki tool, nice bar on the end and even distribution of force, quite a neat little tool.
Pushed the ears on the washer back.
Out with the 1/2 inch kit.
Smash goes the clutch hub well...fuck me, somebody didn't do the bolt to 32nm!

All four bits of alloy had smashed (where the spring bolts go in to)

So I decided, seeing as I have a complete spare clutch (Doug loves spares) I'd have to drill out outer edge of the hub.
Slammed a few bolts in, made a plate for that, another lever, and it came undone.


That was some highly unexpected thudfuckery was a really neat tool too, much better than the ones I have used on the GN motors and certainly a bit flasher than that pic Asher had with the dirty big crescent lol

Anyhoo, it's a matter of sorting out what goes where once I split the cases and then nip it back together. I have a German DR600 manual, an early DR650SE manual and the DR250 kick start system is fairly similar looking, so plenty of reference.
Going to do Drew's trick to grind down some long nose pliers for a set of cir-clip pliers.