Honda CX500 and Suzuki GN250 Mechanic required

Discussion in 'Australian Motorcycles' started by kenahs, Jul 14, 2004.

  1. kenahs

    kenahs Guest

    Hi All,

    I own a 91 GN 250 and an 81 CX 500. Both need repairs and I am having
    a lot of trouble finding a trustworthy and knowledgable mechanic to
    take them to.

    I bought the gn 250 a few years ago. It had a worn gear change
    spindle. I took it to get it fixed back then at sydney motorcycle
    wreckers when they had to do some other major engine work on the bike.
    They were going to fail it for a pink slip because of this, so I asked
    them to do the work, they did not do the work instead they just
    tightened the bolt on the gear lever and said not to worry about it.
    Over the years I have had the bike the spindle has become more and
    more worn to the point where the lever cannot be tightened on to it
    anymore. I have taken it back to the mechanic and asked how much to
    get it fixed properly, they said don't worry about it just weld it on.
    As I was ready to sell the bike I decided to do this, but not through
    them, as they had the bike for 3 months the last time and I got it
    back with a dented up front mudguard.

    I took it to a friend who was a welder and fellow motorcycle
    enthusiast. Instead of just welding the lever, we chose to build up
    the spindle with weld so the lever could have something to attach to.
    Weld was applied to the spindle and the lever hammered back on. In the
    process the spindle went through the other side of the case.

    We removed the case and welded it up properly, however we didn't have
    a replacement gasket. Inside the motor we found a metal "tooth" broken
    off from somewhere which we were unable to spot from that side of the
    engine. The bike was reassembled and limped home. It still needs a
    replacement gasket, as well as the unknown part which is broken and
    ideally a new spindle and gearshift lever. I previously tried to get a
    gear shift lever at the wreckers and they told me it would take too
    long to get one off come back another time. I have tried various other
    methods previously to welding, to fix the spindle including liquid
    metal, a metal sleeve, and wire windings. None of these were

    It's time to hand it over to a good mechanic. Engine schematics or a
    workshop manual would also be helpful.

    The CX 500 has a problem with the charging system. Its symptoms

    -Intermittent Power,
    -battery not charging, and
    -bike stalling when the battery is low.

    I took it to an auto electrician with the workshop manual and asked
    him to do the tests in the manual and tell me what the problem was. He
    told me it was the rectifer regulator needed replacing, which he did.
    Several hundred dollars later I get the bike back and it is the same
    as when I took it . I called him straight back and he said well I
    guess the rectifier regulator I just put on was faulty also, bring it
    back and I'll put another one on, and that'll cost the same again. I
    asked "why didn't you test it before you put it on?", he said he did
    and that it was charging weakly he thought it would be ok.

    So I sourced another regulator rectifier and replaced it myself. The
    problem was still there. Now the rectifier regulator has been replaced
    twice without solving the problem. Both rectifier regulators test ok
    when tested with the multimeter. The Alternator tests ok. The Battery
    is brand new and fully charged. All connectors have been dismantled
    and cleaned. When testing the charging of the battery when the bike is
    running, it is low and weak, but it does charge slightly, though not

    If you could recommend someone to me who can repair either, or both
    bikes, and their contact details, I'd be really grateful. I am in
    Newtown, NSW, so am looking in the Sydney area.


    kenahs, Jul 14, 2004
    1. Advertisements

  2. In on 13 Jul 2004 21:57:25 -0700
    I have had some experience with MMT in Granville, they seem competent
    and clueful.

    I've talked to Tony Magri in Kingsgrove, he seems reasonably together too.
    Only work he's done for me is fixed a flat, but it was done well and
    with care.

    Realise that the GN repairs will cost a packet, I suggest you spend
    some time sourcing bits for it. try Brisons or Penrith Wreckers, they
    specialise in the old stuff. Might even get a whole new motor!

    With electricals, I think you are stone out of luck in Sydney. Hy Beam
    in Alexandria have done good work for me with starter motors, but no
    idea if they are willing to do other bike work.

    If no go, then perhaps get onto Ryans and ask if they can recommend a
    sparky, someone who knows old brit bikes might be willing to work on
    the CX. Or Gowies might know someone. Or get a copy of Just Bikes from
    the newsagent and start calling classic bike clubs for leads.

    You could perhaps call Small Coil Rewinds in Geelong, he could have some
    ideas about what to try and maybe even know who in Sydney could help.

    Tony Magri Motorcycles
    167 Kingsgrove Rd Kingsgrove 2208
    (02) 9554 4222

    MMT Motorcycle Services
    4 East St Granville 2142
    (02) 9637 0277

    Brisons Motorcycle Wreckers Pty Ltd
    5 South St Rydalmere 2116
    (02) 9638 7140

    Penrith Motorcycle Wreckers
    Unit 20, 121 Coreen Ave Penrith NSW 2750
    ph: (02) 4721 2116

    Hy-Beam Electrical Service
    296 Belmont St Alexandria NSW 2015
    ph: (02) 9557 2980
    Small Coil Rewinds" (03) 52721659
    Zebee Johnstone, Jul 14, 2004
    1. Advertisements

  3. kenahs

    sharkey Guest

    Such is the way of elderly bikes. And for the value of either
    of these bikes, you can't _afford_ a trustworthy and knowledgable
    Bugger. Oh well, live and learn. Learn not to hit aluminium
    castings with a hammer, mainly. Tooth is probably out of the
    gearbox somewhere. Someone will curse me for this, but if it's
    still ridable ignore it.
    Best ever method: Mark correct position. Remove gear lever.
    Remove spindle. Put lever back on spindle in correct postion,
    clamp in vise. Drill carefully (use a drill press) through
    the lever clamp, spindle, lever clamp on the other side.
    Return parts to bike. Fit steel pin through hole, old
    allen keys work well.
    Hard to tell off the top of my head ... buy a $6 multimeter from
    Dick Smiths and check the battery voltage when off, idling and
    running > 3000rpm. Should be 11-12V, 12-13.5V and 13-14.5V
    respectively, or thereabouts.

    Also, check the battery earth lead if you haven't already.

    Might be worth looking here too:
    To change a rec/reg to another dodgy one? ****, did you get
    ripped a new one.

    sharkey, Jul 14, 2004
  4. kenahs

    Johnnie5 Guest

    one option is to make a keyway on the shaft using welds and grind a channel
    in the lever

    something like this
    (pissweak ascii artwork) -o-
    this way it will have something to lock it into place
    which you say give me money back ya cahn or fix it properly , but
    you wont be getting any more money , your pisspoor diagnosis is your problem
    and i am not paying for your inability

    so you either have a pissweak stator winding (common on CX500's )

    or poor earthings

    you need a multimeter and go through everything

    how is your battery??

    electrics arent all that hard, you just need a method of going through it
    youself , see above to the helpful hints :)
    Johnnie5, Jul 14, 2004
  5. kenahs

    barry taylor Guest

    you need to talk to the gurus at


    barry j taylor < >
    ICQ# 21309897: Ulysses #25871: netrider 549
    AIM: ursus australis
    __ __ __ _ __
    /__/ / /__/ /_ /_\ /_ /
    /_ / _ / /__/ /__ / \ / \ ...Vrroooom!

    bear on a CX500 Sports -------> ----------->Vroom!!
    barry taylor, Jul 14, 2004
  6. kenahs

    Stuart Thyer Guest

    I don't always believe mechanics when they say don't worry about it, but
    given the cost of actually replacing the spindle, they were probably doing
    you a favour because the value of the bike would never be particularly good.

    Having said that, if you're waving money under their noses and they still
    don't want to fix it, then more fool them.

    Good luck repairing

    Stuart T
    Stuart Thyer, Jul 14, 2004
    1. Advertisements

Ask a Question

Want to reply to this thread or ask your own question?

You'll need to choose a username for the site, which only take a couple of moments (here). After that, you can post your question and our members will help you out.