GTS250
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Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Sun Oct 20, 2019 6:26 pm quote
This bike has become my go-to ride for quick runarounds. Itís fun to ride and itís loud when I get in the throttle. If I drive slowly (just barely beating cars off lights) itís only a bit louder than before but twist the throttle and the exhaust makes itself known. It also has a delicious backfire that I rather like.

November is getting closer and thatís when the engine work can get started. Almost tempted to not change anything as itís so fast already...but I MUST see what this head will do.

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Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Tue Nov 26, 2019 6:55 pm quote
Malossi head sent off to be machined today. As soon as itís back this project can move forward to the next step.
Addicted
2010 gts 300 super. 09 MP3 500 lite
Joined: 02 Apr 2013
Posts: 565
Location: tampa
Tue Nov 26, 2019 11:21 pm quote
what machining is being done?
Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Wed Nov 27, 2019 2:15 pm quote
jerryd wrote:
what machining is being done?
I followed the thread over on the Aprilia forum where Micah from AF1 in Austin took a Malossi 4v head and opened it up to flow even more. I asked him to do the same work for me.
Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Tue Jan 21, 2020 6:39 pm quote
This projects been dormant a while Had a few hours today so decided today was as good as any to begin.

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Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Tue Jan 21, 2020 6:40 pm quote
And the motor as is prior to taking off the old cylinder and head.

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Hooked
300 super sport Full Malossi and carbon Edition
Joined: 26 Nov 2016
Posts: 133
Location: Netherlands
Wed Jan 22, 2020 10:32 am quote
Polini 294cc or Malossi 282 cc?
Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Wed Jan 22, 2020 7:27 pm quote
Malossi 269. Itís a 250. Got a lot more done tonight. One of the dowels is stuck in the cylinder so Iíll be ordering that and a few other parts Iíll need to get this thing back together. So far so good. Fun work after my day job.

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Addicted
2006 GT200L "Lone Star"
Joined: 15 Jan 2019
Posts: 627
Location: Texas
Thu Jan 23, 2020 7:11 pm quote
rob g wrote:
This projects been dormant a while Had a few hours today so decided today was as good as any to begin.
What scissor lift are you using under the frame? It's a lot more compact than mine.
Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Fri Jan 24, 2020 5:11 am quote
Extreme Max 5001.5044 5001.5044... https://www.amazon.com/dp/B0196PAZ1S?ref=ppx_pop_mob_ap_share
Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Fri Jan 24, 2020 5:44 am quote
Taking my time as I wait for my parts to get here. Dowel supposed to arrive Saturday. Itís small, skinny, and I gave up trying to pull it out of the old cylinder. Itís the only part that by messing up has halted progress. Fits between the cylinder and the block so I canít even get that first piece on. In the meantime here are all the small parts from the head and a couple other places.

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Member
LX50 ish
Joined: 06 Dec 2019
Posts: 10
Location: Canada
Fri Jan 24, 2020 6:56 am quote
Killer. There is something about a quick scooter that is satisfying in many ways that cant be replicated. I think its partially "underdog scenario" mixed with the fact that it's more fun to operate a slower thing fast than a fast thing slow. I have scoots and bikes, my most proficient bike is an RSV4 which see's mostly track service; it can be operated on the road but when it comes time to grab something and go, the decision is 90% scoot.
Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Fri Jan 24, 2020 11:28 am quote
Full agreement there. These bikes are already super quick off the line. I canít wait to see how much quicker this one becomes.

While I wait for my parts Iíve turned to figuring out where to mount my adjustable fuel pressure regulator to get my fp up from 2.5 to 3.5 bar. I want plumb it in and have realized that fuel injection line is different from regular fuel line and I donít know what size line to buy nor can I get the fittings I need for the fpr. Anyone know the size of the fuel delivery and return lines on a GTS250?
Addicted
2006 GT200L "Lone Star"
Joined: 15 Jan 2019
Posts: 627
Location: Texas
Fri Jan 24, 2020 7:25 pm quote
rob g wrote:
Thanks. Ordered one.
Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Sat Jan 25, 2020 2:59 pm quote
Good buy! Youíll be happy with that lift.

Ok so for the first time ever both Amazon and FedEx came early on a Saturday. Delivered the dowel I needed and my assembly lube. $7.49 at the local auto parts vs $5.99 on Prime meant Iíd wait the 2 days and save $1.50.

Put in the dowel and assembled the cylinder and piston.

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Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Sat Jan 25, 2020 3:01 pm quote
Next I put on the head and reinstalled the cam and rocker arms.

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Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Sat Jan 25, 2020 3:23 pm quote
Spent extra time trying to get the timing chain perfectly aligned. Hereís what the gear ended up looking like.

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Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Sat Jan 25, 2020 3:24 pm quote
And the view from the sight hole to see the mark on the crank.

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Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Sun Jan 26, 2020 4:50 pm quote
We have success

Did everything I could to get this sucker back together before sunset. Still have to go back and finish up some odd and ends but I couldnít go to sleep tonight without firing it up today. Turned the key and in under 2 seconds it fired up. Took a 3-4 mile joyride and now itís back in the garage. Iím sure there will be bugs to work out but Iím pleased with where things are. A fun bike to ride is suddenly a lot more fun.
Ossessionato
2010 ThunderFly 190, 2008 250 GTS
Joined: 29 Apr 2011
Posts: 2698
Location: Springboro, OH
Wed Jan 29, 2020 12:49 pm quote
Great work on this GTS. I like the subtle aesthetic bits you've selected.

The motor work is exciting as well. I'm guessing the headwork done on the Malossi V4 head was a polish and port job...should help a bit.

I have the same PM Tuning exhaust on my GTS and my reaction to it is the same as yours...rather quiet unless you crack the throttle open aggessively and the small backfire when closing the throttle and decelerating is a bit of fun.
Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Wed Jan 29, 2020 1:33 pm quote
Thanks CrazyCarl
This was a lot of fun. Yeah it was some light port work, taking what Malossi did and making it better.

You hit the nail on the head about the PM exhaust and the deceleration popping. I even throttle up and coast to hear the tone it makes as it coasts down. Great conversation starter on group rides too.
Addicted
2006 GT200L "Lone Star"
Joined: 15 Jan 2019
Posts: 627
Location: Texas
Wed Jan 29, 2020 3:34 pm quote
rob g wrote:
Good buy! Youíll be happy with that lift.

Ok so for the first time ever both Amazon and FedEx came early on a Saturday. Delivered the dowel I needed and my assembly lube. $7.49 at the local auto parts vs $5.99 on Prime meant Iíd wait the 2 days and save $1.50.

Put in the dowel and assembled the cylinder and piston.
Did you put the little o-rings around the studs before you put the head on? I'm just wondering. Just had to pull my head a second time 'cause I missed that step. Fortunately, I didn't start the engine. I bled a bunch of coolant into the oil pan and on the ground overnight, so I knew something was wrong.
Hooked
2008 GTS250, 2009 S150, 2017 GTS300Super, 2006 GT200
Joined: 18 Oct 2014
Posts: 276
Location: Houston
Wed Jan 29, 2020 3:47 pm quote
Yes I put on the o-rings. They actually came with the new head in the bag of gaskets.

When you put them on make sure you cut a piece of plastic about 2X2Ē to cover the threads. Grease the o-rings up and theyíll slip right over the plastic and threads onto the smooth part of the studs.
Addicted
2006 GT200L "Lone Star"
Joined: 15 Jan 2019
Posts: 627
Location: Texas
Wed Jan 29, 2020 4:30 pm quote
rob g wrote:
Yes I put on the o-rings. They actually came with the new head in the bag of gaskets.

When you put them on make sure you cut a piece of plastic about 2X2Ē to cover the threads. Grease the o-rings up and theyíll slip right over the plastic and threads onto the smooth part of the studs.
I ordered my head and cylinder base gaskets ala carte, and didn't think to replace the o-rings, even though they were 13 years old and clearly were dried out and cut up from pulling the head and cylinder.

I saw the plastic bag trick on one of Robot's videos when I was trying to figure out what I did wrong.

Nice looking project. I also just used the lift you recommended. Worked like a charm.
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