What is being used requires care – and more-so with age. In addition to all the riding experiences, the technological side should not be neglected. Here is the first report from the workbench.
We had just returned from Biarritz and on the way back we decided to conquer a former military road in the Alps the following year. Motorcycles with a soul and a past were a necessity. So the shopping list was written:
1x motorbike with studded tyres, old, preferably two-stroke, cheap please.
In the garage at home was a Suzuki TS50, bought cheaply from a colleague, then gifted away, restored … another story. In any case it made sense to enlarge this very small Suzuki collection and save the time-consuming comparison with other models or even more strokes. Or, it makes sense if you have a big weakness for old motorcycles. Let’s make it short – not far away was a TS250 from the same model year, half restored, and for a fair price. The previous owner had had to buy it from his father-in-law after a decision of the family – because the father-in-law tended to rattle home with it from the pub through the forest with a “full tank”. The restoration had been aborted and she should leave the family for good. Sounds exactly like the type of previous owner one wishes for. So, we loaded it up and hauled it home.
At home, you finally have a look at what your cash changed hands for. The frame was painted black and marbled orange. The primer and the paint hadn’t got along so well. The electrical system was not complete and the interior of the engine was an unknown. On these Suzuki models you can only change the oil seal between gearbox and crankcase when the block is open – perhaps it was ripe for refreshment after almost 40 years. So we slept on it for only one night and the decision was made that this will probably be a bigger project, even if it is manageable. The first step, of course, is the disassembly and then taking one large box to your trusty powder coater and one to your trusty galvanizer. By the way – powder coating is not recommended for off-road use, because after five kilometres at the most, your eyes tear up when the first large stone caresses the frame’s underbeam.
While everything was in the coating process, the engine went in the wash. There was a surprising amount of dirt and a little bit of wear in the engine. No surprise there. When everything is already open, you can rework the ports and free them from the as-built throttling. I wonder how much more power she might have in her?
The powder coater was quick and did a clean job as usual (all threads and fits were masked). The machine was already standing on her own feet quite quickly, after only a few evenings in the basement. So far, we were still close to stock – but you can’t deprive yourself the joy of making something better. So we put in a 12V generator, added a USB-socket and LED spotlights compliments of China, and finally, the feature of amusement for all hardcore travellers (and a blessing for my delicate office hands): heated grips.
But now the whole thing looked a bit bland. The painted parts were well made, even if the choice of colours was more in line with someone who had paid for his driver’s licence with Reichsmark. Due to the little remaining time until departure, the inevitable MOT date, test rides, and above all the acute disinterest to paint a motorcycle, the colour should however come from somewhere else. The seat was cut slightly flatter and sent to the saddler with a fabric sample from the junk drawer. After extensive research on her part, she pulled a film under it, selected beautiful piping, and delivered it in perfect craftsmanship.
The test drive went off without a hitch and the MOT passed – the Suzuki was ready for the tour.
Such a project never ends, of course. After the first tour it became obvious that a little more luggage had to be taken along, that the installed shock absorbers were absolutely useless, and that the no-longer-stocked exhaust and headlights needed protection against flying debris. The original luggage rack is not available for any amount of money or good words – neither here nor in Japan. The last chance – Veterama Mannheim. Alas, no luck, but similar tube constructions as basis were to be found. A long afternoon in the garage turned the tube into a suitable luggage rack. With aftermarket YSS shock absorbers the driving became worlds better but is still not quite as it should be. The next shocks will be adapted to the rider, luggage (around the belly button as well as on the rack), and riding style. Protection for the exhaust and headlights were offered again by a few great parts from the friendly Chinese.
As it stands there today, the Suzuki has behind it several thousand kilometres on gravel and road without any problems, always starts at the latest on the second kick and after it was only meant as fun for one summer, it will probably stay in the family forever.
Updates, improvements and more pictures from the workshop can be found on Instagram.
12-volt generator: http://www.powerdynamo.biz/
Hidden heated grips: https://www.coolride.de/
Powder coating: https://www.goetz-pulverbeschichtung.de/
Saddlery: https://www.trueblue666.com/
Leave a Reply