2006 GN250 Complete Rebuild NZ

Plus 12 more

I took a GN250 that was literally in a hundred or so pieces and rebuilt it from parts in my shed.
This was quite the undertaking for an office worker, psuedo back yard mechanic!
Armed with a downloaded internet manual, GN250 club nz Facebook group and sheer determination, I made it happen!

I broke bolts, scraped rust, cut off seized bolts, ordered parts and tools, pulled my hair out until I was successful.
Raw determination and love for motorcycles was important!

Not for a second did I regret my decision, just one step, one challenge and a lot of WD-40!

Now I get to ride a bike I literally made. The owner who sold it to me was speechless when he saw it too!

Step 1: Pickup GN250

Saw a GN250 on local marketplace - it was in parts and hadn’t been on the road for 6 years.
Owner always meant to cafe racer it out.
I thought about how it would be fun to make a bike from parts - although basic, there seemed to be a lot of them out there

Step 2: Sand, rust wheel and undercoat frame

Plus 2 more

Found some proper undercoat, decided to clean up and enamel frame

Step 3: Start fitting parts

Plus 1 more

Fit the parts to the frame - get the front wheel and rear wheel on the frame

Step 4: Fit engine and start wiring loom parts

Plus 3 more

Fitted engine myself, start connecting electrical parts and loom. Fit battery, working towards getting where engine can be started

Step 5: Wiring, bulbs, carbs

Plus 2 more

My aim here was to try get the bike running in the next week. I probably fitted the tank on and off several times trying to decide where the wiring went

Step 6: Carb challenges / exhaust hole

Plus 2 more

Wasted a few days mucking about with the carb, trying to understand how it worked. (Fuel was overflowing)
Liberal use of WD-40 at this point too!

Step 7: Trying to get her roadworthy

Plus 3 more

Needed pillion pegs welded back on, brighter bulbs, rear brake was causing head aches.
Had a bit of a break down event while testing - carb had to come back off for a fix. That was fun!

Step 8: Victory!

Plus 1 more

After a 43 day build - and another week to sort out warrant/road worthy issues! She’s done!
A few celebration rides and coffee runs to cap of a very interesting (lots of learning) project!

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