Suzuki Across Fixup 2

GSX250F Junker fix up - Page 2 - Aussie Street Bikes Page 1 of 27
Register Community Calendar
User Name User Name g Remember Me?

b
c
d
e
f
Aussie Street Bikes > General Bike Topics > Member Projects Password Log in
GSX250F Junker fix up Forgot Password? Join Us!
Mountain Bike Bikes Motorcycle Racing Racing Bikes Super Bikes
Velosophy Bikes Huge range and best prices at Australia's hottest bike shop! www.velosophy.com.au
99 Bikes Online Bike Shop Browse Our Wide Range Online. $7 Flat Rate Shipping. Buy Now! 99bikes.com.au/shop
Lake Jindabyne Hotel From $95/day. Lake Front Rooms,Free Wi-Fi, Hot Breakfast , Book Online! www.lakejindabynehotel.com.au
10-12-2010, 09:32 PM
Glen haha yep! i did exactly that with one of the fork legs, piece of box section over the allen key breaker bar style. ive had Securabike Parking
Rider to use it so much i swear there should be a suzuki special tool number for it Rails, Racks, Cages & Lockers
bikes parked
www.ledasecurity.com.au
Ill give the autosol a go as well, i think i saw some in the shed hehe. Still have a lot to learn about cleaning and stuff..
Motorcycle Parts On Sale
Motorcycle Parts for Cruisers.
and lol at the fork design, arent the hyo motors suzuki based too? Wouldnt be too surprising if they took alot of the 7 Business Days!
older designs and remanufactured em. if it works i guess! www.CruiserCustomizing.com
Zoosk® Dating Site

Whack up a thread on your hyo if you can!, i love pouring through picture dump threads. could read em for hours Online Dating That Works 50+
Join Free!
www.Zoosk.com/
Join Date: Oct 2010
Windows XP Driver Upda
Posts: 433 Windows XP Drivers Latest Do
Certified. (Recommended)
Location: NSW
Windows-XP.DriverUpdate.net
Rep Power: 63
'91 Suzuki Across
Did you find this post

Sponsored Links
Aussie Street
Bikes
Advertisement
11-12-2010, 04:27 PM
Valen I found that if there has been a seal in place for a while it'll be there and working "ok", but the oil etc makes em swell, so as soon as you
Pillion against, your stuffed basically lol.
Join Date: Dec 2010 On my missus zeal though I got some break caliper seals from the UK, the pressure seals were fine, but the dust seals were over sized and I couldn'
Posts: 1
back in, thankfully the old ones fit back in.
Location: NSW I was pondering putting boots over her forks, but i think she wouldn't like it, she likes the shiny.
Rep Power: 2
I do need to replace her steering bearings, but
it hasn't fallen off yet,
it looks like an ass of a job,
I really CBF right now lol.
http://www.aussiestreetbikes.com/forum/showthread.php?s=8440d451cdc105ed803d4... 29/04/2012
11-12-2010, 04:37 PM
Glen Bit of an addenum to that forks post,

Rider
Heres the solution if the damper rod bolt wont come out or just rotates with the part.
Suzuki special tool Attachment F!
Join Date: Oct 2010

Posts: 433
Location: NSW
Rep Power: 63
'91 Suzuki Across
AKA 24mm nut welded to large random piece of tubing.
What this does is engage in the end of the damper rod and stop it rotating while you undo the bolt. Or alternately when your doing it up to
Wrapping it in glad wrap or something to stop it scratching the staunchion helps no end Here it is in action!
Got the dust seals ordered from action MC so ill get those done wednesday. Water pump is up next
11-12-2010, 04:47 PM
Glen
Rider Originally Posted by Valen
I found that if there has been a seal in place for a while it'll be there and working "ok", but the oil etc makes em swell, so as soon as you remove
sealing against, your stuffed basically lol.
On my missus zeal though I got some break caliper seals from the UK, the pressure seals were fine, but the dust seals were over sized and I cou
calipers back in, thankfully the old ones fit back in.
I was pondering putting boots over her forks, but i think she wouldn't like it, she likes the shiny.
Join Date: Oct 2010 I do need to replace her steering bearings, but
it hasn't fallen off yet,
Posts: 433
it looks like an ass of a job,
Location: NSW I really CBF right now lol.
Rep Power: 63
Hahaa fork boots would be heaps retro, do it Then get cracking on the ape hangers
'91 Suzuki Across
15-12-2010, 09:45 AM
Glen Woo action MC got my fork dust seals to me quick smart. Shame the retaining clips are rusted to HELL >:
Rider
Join Date: Oct 2010

Posts: 433
Location: NSW
Rep Power: 63
'91 Suzuki Across
But on the upside all my 304 stainless bolts nuts and washers + black anodized well nuts came for the rebuild. Happy days
Cleaned up the crusty wheels a little and bunged on the new sprocket. i wanted to put stainless glenloch nuts on the sprocket as well, but
beyond my budget for now. I thought the front rotor carrier was black for a while there. turns out its actually gold under the filth
Will plow through the build on the weekend
20-12-2010, 04:56
PM
Glen Right-o, on the home straight now. Time for another photobomb
Rider
Suziparts send all the bits for the forks and some other little pieces i needed quick as so heres the..
Fork Reassembly
So with the fork guts spread out on the table i cleaned them up a little and started with the reassembly.
Damper rod and spring drops down inside the stanchion and pokes out the bottom
Join Date: Oct

2010
Posts: 433
Location: NSW
Rep Power: 63
'91 Suzuki
Across
That lot then gets dropped into the fork bottom and the damper rod bolt screwed in. The service guide called for some obscure loctite which
hobbyking kwality loctite will do. It says permanent but its about loctite medium.
Pro-tip - put the loctite right up near the head, that way itll stop it shaking loose but it wont be such a bitch to get out (once youve wound the bolt out past th
comes out easy as).
Didnt have the right attachment to do it up with the torque wrench either, so i had to make one. This random 11mm flat blade attachment for a
threw out years ago will do. Just cut off his head
And with a frightening amount of adaptors to make it all work the damper bolt is finally done up to torque
Next up the "inner and outer" metal sleeves get put on along with the large washer. The service guide says to replace the sleeves. but im already cleaned out
service. So screw them
Time for the fresh oil seals to go to their new homes. Dont be a w*nker and spend that money on a seal bullet. Cause a cut up juice bottle does the same thin
Putting some of the fork oil on the seal helped it go on, but really didnt even need that..
The fun begins here, I didnt have any PVC tubing and without a bike or car couldnt go out to get any to improvise a seal driver from, and cutting the old seals
a driver didn't work either as they turned to dust.
So i went for a wander around the block and found someones old crusty chopping board and lathed a driver out of it.
its bleeeeeeeding greeeeeennn
Hard to see whats happening but with the fork in the vice and the "driver" on top, i just used a rubber faced hammer and a bit of ali pipe as a drift to push th
position. Worked well. Didnt scratch anything either with all the rags.
Crap photo but you can tell its all the way in when the slot the retaining clip sits in is 100% visible.
New oil seal clips and dust seals tiem
These ones are painted (the originals might have been but damn were they rusted to death) and i dont want them to turn to mush, so i tried
Pinching them together and pushing them in slightly followed by using the plastic seal driver to push them home. All good.
Why is taking a pic of the inside of a fork so damn hard ;.;
The dust seal just pushes in by hand. Nothing special there.
So thats the arse end of the forks done and dusted. Time for the fluids (thats what she said )
Yet again, not paying for proper tools so another quick home made job suffices. This one is a fork oil level tool to make the oil level equal in both forks. The m
90mm from the top, so the Tube pokes down 90mm from the top of the fork leg and the syringe sucks up all the excess fluid.
Put the fork in the vice with some rags, wouldnt want it to get scratched, although mine are absolutely molested. TYVM previous owner Levelling it up to m
and accurate. Also dont forget to push the fork leg all the way down to take that 90mm reading.
Filling it up. Manual says 400ml so i put in 500ml
Sucking all the excess fluid out, The level is indeed 90mm.
Plop in the fork spring and seat on top slowly, followed by the spacer tube. Dont just drop them in or you might splash some oil out.
With some wrestling around and colourful words the fork cap goes on and those fork legs are freakkkinggg done
Slide em back through, do up the bolts to torque while making sure the top of the fork leg (not the cap, the leg) is 31mm from the top of the
FINALLY DONE and down off the A frame. Definitely investing in some bike stands some time (thats probably a lie)
Doing the waterpump as i type and then all that remains is to fill it with oil again, balance the carbs and slap the body work on then pray to
20-12-2010, 09:58 PM
extermin8tor Great finale to the fork seal job I used a thin plastic bag doused with fork oil to get the seals on, after buggering the seals up the time before I w
Rider take chances
You were probably better off with the DIY seal driver, I took mine to a shop to get them to bang them in and the bastards scratched the
I also just filled both forks up with 400mL without adjusting them, is that bad? I figured since I rebuilt both legs it should be fine!
Join Date: May 2010

Posts: 1,548
Location: SA
Rep Power: 443
'03 Suzuki GSX-R 600
21-12-2010, 07:11 AM
ItsaGixa Dude, nice effort on the bush mechanics...i had an across a while back, awesome bike, never had any issues with it....all though i didnt give it the
Pillion 1st Class deserves....have you done the bafflectomy to the xhaust yet?
Join Date: Sep 2009

Posts: 133
Location: SA
Rep Power: 3
21-12-2010, 05:08 PM
Glen Cheers, i dunno if the oil level really affects them that much. TBF i dont think it really does in a standard style fork, long as it fills the
Rider there so not too sure haha.
+ nawh havent touched the exhaust yet unless someone elses done it. I was tempted to put one of those cheap ass ebay cans on cause this
cbf for now
Annnddd the last major mechanical piece of the puzzle i sure freakin hope.
Water pump overhaul
After doing the head gasket and still having water piss into the oil i was getting pretty worried thinking it might be a cracked block or head. But pour
Join Date: Oct 2010 diagrams it seems the water pump backs into the sump, and if the seals start leaking then itll all dump into the sump which is what i reckons
Posts: 433
First oil fill up after the headgasket. FFFFFFFFFFFFFFFFFFFFFFFFF
Location: NSW
Rep Power: 63
'91 Suzuki Across
ze pump in all its crusty glory
2 of the 5 bolts came out but the others... holy sheeet. those were siezed in good and well. Freeze spray, BFH and an impact driver got
one was just not budging.
Ended up just saying F' it and drilled the head off. The heat must have loosened it up cause the remenant threaded out by hand pretty
After probably 20 years or more the pump was well locked into place, so 2 m6 bolts threaded in against the side of the crankcase pulled it out
Out she comes! Pretty sure this is were its been leaking out of..
Pretty damn sure.. The oil seal is completely shitted and the other one is half of another seal thats broken in two
Yet again Ray sent the parts for the pump which were surprisingly cheap. Sydney bearing supplies had the bearing i needed for a fiver.
Pickin the seals out of the bearing (pretty sure they dont even sell them without seals now?)
Cool trick to installing the bearing. Chuck the part in the oven, 150c for 15 minutes and then using a socket in the bearing push it in.
cause the aluminium has expanded. Saves wrestling around with presses and the like anyway.
Put some moly grease around the seal and that slid in by hand. The top of the pump surface i had to lathe down a few thou cause i gouged it
mechanical seal Turns out they adhesive the thing in >__>; Only worked out it needed some heat blasted on to it after id molested it with a drif
The mechanical seal is tricky. its a really tight press fit but the part is also really thin so its easy to wreck (would rather not wreck all
My dodge solution was to use a pulley id bored out for something else that fit over the part nicely and a long bolt and nut to force it in. Slapped som
sides for a bit of insurance also. (obviously the excess is wiped up )
Installing the new ceramic thrust washer and rubber cap
Plop that in through the seals and bearing followed by the e-clip
Then it can go back in the bike finally! how i have waited for this day XD I replaced the wrecked phillips head bolts with some 306 stainless steel soc
hopefully i wont have to deal with that crap next time (if there is a next time.. hopefully not).
Getting the parts for the forks the other week i went a bit spastic after seeing all the clearance berik gear at action, So i splurged a bit
exhaustion, but the textile ones just feel like a pile of rags sewn together so leather for me.
23-12-2010, 12:20 PM
Burkey Awesome thread.

Rider
As for the leathers.. nice honestly I do not feel much hotter in my leather jacket than I did my textile one so I would not sweat it (zing!)
Join Date: Aug 2009

Posts: 771
Location: NSW
Rep Power: 226
01-01-2011, 02:32 PM
Glen How was everyones new years? Pretty massive one here so just typing this to distract from the hangover
Rider
Did the carbs day before last. I thought they needed a rebuild cause it ran like a bag of crap, idling too high then too low then hesitant
doing nothing etc.
So i cleaned them out all nice like. The insides of the funky across carbs -
Join Date: Oct 2010

Posts: 433
Location: NSW
Rep Power: 63
'91 Suzuki Across
Measuring the float level. top of the gasket surface to the top of the float with it resting on a level surface. Checks out to be perfect
The needle clip things are new in one bank of carbs but old in the other so i heated the old ones up slightly to bend them out and they fit
the less ill grab some new ones.
With the lot back on and the throttle cable lubed as i thought it may have been sticking causing the hanging revs, nothing really changed >: Still did
before.
Sooooooooooooooooooo i made a manometer with some stoppers i got off ebay, some glass olive oil bottles (dont ask what i used the oil for
tubing from bunnings
The problem was soon pretty clear as the level in one bottle shot instantly to full, WAYYYY off balance. Some tinkering around later
Perfect!
Had to lean the mixture screws 1/8th a turn from the factory recomendation cause it dropped about 100-200rpm under idle before
Totally amazed by how accurate the manometer is though, 1/8 of a turn on the balancing screw sends the level shooting to maximum and just puttin
pressure on the screw without turning it results in a visible change in level. Well pleased with that!
Ill have to get some videos of it working next time i balance it. Dont want to do it again cause it took so long to get perfect lol!
Just gotta get the pump plumbing sorted and rivet the chain (stupid regina solid pins ARHGH!) then i can look into respraying the fairings after ive ri
The paint is well tatty.
Going for a sleep now. damn this 40c BS weather. not good for drinking XD
01-01-2011, 04:37 PM
extermin8tor Always looking forward to seeing updates Its a shame my internet is capped for the next 5 days, I couldn't get some of the pictures to load, tooo
Rider sloooooooooow!
I will be changing my clutch on Wednesday when my parts arrive, as I am stuck at home with a broken ankle
Happy New Year
Join Date: May 2010

Posts: 1,548
Location: SA
Rep Power: 443
05-01-2011, 12:44 PM
highside @Glen.
LOWSIDE Happy new year and double thumbs up for a great thread.
Funniest comment you have made to date?
the one regarding CBF'd installing a cheapo can from ebay.
Considering the custom tools, tooling etc that you have done to progress the build to this point and then seeing your post citing laziness as your reas
a new can? Priceless lol.
go ahead and do it bro.
Are you going to spruce up the fairings etc as well?

__________________
Join Date: Sep 2009

Posts: 7,909
Location: VIC
Rep Power: 3896
'10 Triumph Street Triple R
05-01-2011, 04:46 PM
Glen Yeah i know, but its not really essential yet and i just know if i do take it off again ill be forced to get all the headers painted, and replace the exh
Rider studs + all the rest. So im saving myself, from myself
Saying that tho im still keeping an eye out for a cheap stainless can. Maybe this one?
You Tube
Join Date: Oct 2010

Posts: 433
Location: NSW
Rep Power: 63
'91 Suzuki Across
Dunno. dont want to be a complete tool with some wailing banshee bike moving at 50kmh XD
As for the fairings hell yeah, There mostly in nice condition sans the paint which have been spray bombed big time. The front near the screens been
just epoxied.. its real ugly) so ill have to get that properly welded and sanded back and such before they get done.
Probably will wait a while for that though before getting it looking nice. Worried ill get it all done up then just throw it down the road in the first
anyway haha. Priorities on just getting it working and riding
Bad news on the ankle extermin8tor! Howd you go with the clutch? Thought mine might need the bearing replaced cause it was rattling before i
but turns out that was just the carbs out of balance making all the thudding and noise
Take some pics if you haven't already done it. Wouldnt mind seeing a run through of how the clutch goes.
As for the bike largely the same. have to run out and pick up a new flasher relay as this one is knackered or made for a lower wattage bulb. Might gr
for the chain too cause this solid pin regina rivet chain is just a right prick to get together even with a little press i made.
Speaking of globes how hard is it to find a 23w 12v one. OMFG! had to go on a round the world journey to find the freaking things.
10-01-2011, 09:54 PM
Glen Okay bike is done! ill throw up some pics of the last few things later.
Rider
But for now i need to get rego sorted and have a few q's if anyone knows.
Need to get it blue slipped and theres a place about a km down the road that does em.
Only thing im not sure about is IF i can ride it down there to get it done. The RTA states you can take unregistered vehicles down to get registered b
what the ruling is on unroadworthied bikes?
As always the rta site is rather vague in that regard and it would be rather shyte to have a trailer the bike 1km up the road lol but none the less
risk a pineappling from the cops over it
Join Date: Oct 2010
Posts: 433 Thanks.
Location: NSW
Rep Power: 63
'91 Suzuki Across
« Previous Thread | Next Thread »
Copyright © 2010 Aussie Street Bikes. All rights reserved.

The AUSSIE Network: Aussie Street Cars | Aussie Gym Junkies | Aussie Mountain Bikes
All times are GMT +8. The time now is 07:30 PM.
Powered by vBulletin. Copyright ©2000 - 2012, Jelsoft Enterprises Ltd.
Powered by vBadvanced CMPS v3.2.2
Like 10 people like this.
Contact Us - ASB Shop - Aussie Street Bikes - Terms of Service - Top

Suzuki Across Fixup 2

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Suzuki Across Fixup 2

Hochgeladen von

Copyright:

Verfügbare Formate

GSX250F Junker fix up - Page 2 - Aussie Street Bikes Page 1 of 27

Register Community Calendar

User Name User Name g Remember Me?

Mountain Bike Bikes Motorcycle Racing Racing Bikes Super Bikes

Zoosk® Dating Site

'91 Suzuki Across

Did you find this post

Did you find this post

Glen Bit of an addenum to that forks post,

Suzuki special tool Attachment F!

Join Date: Oct 2010

'91 Suzuki Across

AKA 24mm nut welded to large random piece of tubing.

Did you find this post

'91 Suzuki Across

Did you find this post

Join Date: Oct 2010

'91 Suzuki Across

Will plow through the build on the weekend

Did you find this post

Join Date: Oct

its bleeeeeeeding greeeeeennn

New oil seal clips and dust seals tiem

Why is taking a pic of the inside of a fork so damn hard ;.;

The dust seal just pushes in by hand. Nothing special there.

Filling it up. Manual says 400ml so i put in 500ml

Did you find this post

Join Date: May 2010

'03 Suzuki GSX-R 600

Did you find this post

Join Date: Sep 2009

Did you find this post

Water pump overhaul

'91 Suzuki Across

ze pump in all its crusty glory

Installing the new ceramic thrust washer and rubber cap

Did you find this post

Burkey Awesome thread.

Join Date: Aug 2009

'09 Suzuki GSX-R 750

Did you find this post

Join Date: Oct 2010

'91 Suzuki Across

Did you find this post

Happy New Year

Join Date: May 2010

'03 Suzuki GSX-R 600

Did you find this post

Are you going to spruce up the fairings etc as well?

Join Date: Sep 2009

'10 Triumph Street Triple R

Did you find this post

Join Date: Oct 2010

'91 Suzuki Across

Did you find this post

'91 Suzuki Across

Did you find this post

Mountain Bike Bikes Motorcycle Racing Racing Bikes Super Bikes

Mountain Bike Bikes Motorcycle Racing Racing Bikes Super Bikes

« Previous Thread | Next Thread »

Copyright © 2010 Aussie Street Bikes. All rights reserved.

Like 10 people like this.

Contact Us - ASB Shop - Aussie Street Bikes - Terms of Service - Top