Trav Mans PE250

[LWC82PE]

Dogleg levers are original for 82. You can not buy new front brake light switches as genuine parts unless you buy the whole lever assembly which is not cheap. You can get aftermarket replica front switches which are vertually identical and have the sme white and orange wires. MCS is the wholesaler for them and you local bike shop should be able to help there.

[Trav Man]

Well I had a quick look at it and the wires and switch base is there but I undo the 2 screws and there is no internals  so I'm not sure if I want to replace it and get it working or not bother with it as I'm only going to use it off road but it would be good to have it there for if I did want it 
Here is a pic of the switch

[LWC82PE]

Yep missing bits, but like i said earler brand new aftermarket replica ones are availble for little $. i think around $12 maybe??? i cant remember exactly but i have used a few before. They come with the case, contact board and internals and sleeved wiring and may even have the screws too. You will find them here in the catalogue www.mcsonline.com.au but you will need to go to your local shop to see if they have any in stock or can just order one in for you. Also try ebay.

[monaro308]

Dogleg levers are original for 82. You can not buy new front brake light switches as genuine parts unless you buy the whole lever assembly which is not cheap. You can get aftermarket replica front switches which are vertually identical and have the sme white and orange wires. MCS is the wholesaler for them and you local bike shop should be able to help there.

I didn't know that Leith,i thought only the 175 had dogleg levers.
Travs lever looks the same as what i put on my 250T because of my crappy wrist.

[lukeb1961]

Sorry to be anal but the 4 stroke DR line overlapped the PE line and came to a halt at much the same time. The DR500 was about the last of the twinshock bunch and got pretty much no updates, though I've been told Germany got two different motors. There was a world wide recession coupled with a jump in the yen's value. That was what killed of development

Which meant the DR600 of 1985-1989 was a mirage? The PE died, not the DR. They dropped it because they saw the 2-stroke road-legal enduro market was heading for catastrophe, the volume was low, the new emissions laws on the horizon made it clear the generic 4-stroke was the only near-term solution. Suzuki's strategic direction had shifted. By 1981-2 the writing was on the wall for anything except the top-line racing RM's and RG's. As to the Yen value, look at the historical exchange rate charts of Yen vs $US - your jump didn't happen until 1984-85! Sure, there was a rise for six months, but compared to the mid-70's, it was low and short-lived - in my opinion, that was not what killed the PE.

[LWC82PE]

Yes well, i suppose the DR line was more made to take over the TS/DS line partly. After 81 that was it for TS's in USA and then they brought out DR's in capacities 100cc and up. They really overlapped the PE line by 1 year really as 82 was when the big change happened and they brought out new DR's in under 400/500 capacities.  Before that there was just the one off DR370, 400 and 500 spead out from 78-81 but not a 'full line of DR's'. Actually now that i think about the smaller DR's in USA were made to be in some ways more DS replacments than and PE replacements which were pretty much abandoned and the SP's were the TS replacements. Remember the USA DR's were a lot different to most other markets and came out with full knobbies, no road gear etc. UK and Australia and others got the SP's rebadged as DR's but they were not the same as the American DR's. It was probably only when people said 'our DR'S are crap, we want the ones that USA has' that we then got a few of the more 'harcore enduro' DR's in Australia, many specially ordered in by dealers and some even brought up to ADR spec at the factory (fitting surplus PE blinkers was one of the things they did) and in the mid 80's to the late 80's there were offered 2 verions of DR250's for example. There was as upgrade in 36mm suzuki forks in 82 and thats why the PE250 and 400Z has different inner and outer legs (outers look the same as 81's but are machined different inside) and the inners have bushings  and all these parts are the same as some of the 82 onwards DR250's. Some new development went into the 84 TS250X and  TS125X and in hindsight that should have been the 'new' PE if it had a few less road/trail characteristics but when set up right and in the right hands they were also capable bikes and sold well. New development went into the DR600 and 650 to cash in on the Dakar/Rallye craze at the time which was really big, especially in europe.

[Trav Man]

Well I got a bit more done today as I changed the handle bars, Front brake cable, rear shockys, put on the new leavers, and the kick start boot.
Now to do:
New chain and sprockets
New muffler
New throttle and cable
Exhaust guard
New seat cover
New plastics and decals
Fit rear chain guide
so the list is getting shorter 

[Trav Man]

Okay so I'm chasing some more info I hope you all can help with.
What is the rate of the std front springs as I'm curious for the moment as I think I might need to up grade for my um    stature

Trav

[Trav Man]

Oh and also now where to get a new header pipe section as mine is cracked 

[tony27]

Try these guys, give very good service & I think there may already be a few people on this forum using their headers

http://www.smebike.com/index.php?route=product/product&path=9_109&product_id=1320

[Trav Man]

Thanks for that mate.
I'll be getting one if I can't get the crack welded as it cracked when I took the factory muffler off as it was a bloody tight fit and had to belt the crapper out of it to get off so I can fit the new alloy muffler 

[Trav Man]

Well I got the cracked repaired and all is good 
Also fitted the new muffler today as well as the new bars and leavers.
Just waiting for the new throttle assy and cable to arrive as then I can get it all back together and ride it



Updated list:
New rear tail light (aquired waiting to fit)
New chain and sprockets (aquired waiting to fit)
Fit rear chain guide (aquired waiting to fit)
Exhaust guard (aquired waiting to fit)
New seat cover (aquired waiting to fit)
New throttle and cable (ordered)
New plastics and decals

[LWC82PE]

Okay so I'm chasing some more info I hope you all can help with.
What is the rate of the std front springs as I'm curious for the moment as I think I might need to up grade for my um    stature

Trav

I just read this on the PE forum

We tested again the stock fork springs and they are a very soft 0.32KG/mm and I have a set of Teknik Motorsports 0.46KG/mm fork springs (P/N 27585) to suit the bike arriving to me Friday afternoon.

If you have been reading on there the past couple of days there was another guy who just fitted a set of new springs to his PE. They were BBR Motorsports brand.

[Trav Man]

Okay so I'm chasing some more info I hope you all can help with.
What is the rate of the std front springs as I'm curious for the moment as I think I might need to up grade for my um    stature

Trav

I just read this on the PE forum

We tested again the stock fork springs and they are a very soft 0.32KG/mm and I have a set of Teknik Motorsports 0.46KG/mm fork springs (P/N 27585) to suit the bike arriving to me Friday afternoon.

If you have been reading on there the past couple of days there was another guy who just fitted a set of new springs to his PE. They were BBR Motorsports brand.

I ended up going with heavy duty BBR fork springs (5mm longer than stock) for a
2004 Honda CRF 150. I kept the stock spacer, and am running 15wt oil, with no
air. What a huge and impressive difference!...

I just went through it thanks for that
I havn't been on there for a while as I might go the same set up

Trav

[LWC82PE]

Find part number 27585 at Teknik. They are 27mm OD x 585mm long which is 5mm longer than stock (580) so cut spacer if your fussy or cut even shorter if using emulators. 3 rates available (at date of that PDF)0.44 kg/mm 0.46 kg/mm 0.48 kg/mm I know one guy who is about 90kgs I think and he got the 0.46 for pe400x He said the suspension shop tested the originals to be 0.36 or 0.32 He said they are way better than the stockers and transformed the bike in a big way. My limited research looking at that PDF says they are from 2002 CRF150

Just some more info copy and pasted.