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GSX250F Junker fix up

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Page 5 of 5 First < 3 4 5 Thread Tools 05-09-2011, 05:08 PM Display Modes #61

Glen
Rider

Hahah fair enough man Was hoping to get the brakes done today but had to tackle another pair of problems i've been putting off till after the Ps test. Kinda wish i did it before cause one of them made the bike a nightmare to do the test on. urgh.

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Join Date: Oct 2010 Posts: 433 Location: NSW Rep Power: 63

First was the constant spark plug fouling on cylinder 4 on a cold start. 2012 Strider Bikes Seemed to happen at random and the The Strider balance bike. Buy online $169. only thing i could think of was the needle valve was wedged open, flooding Free Delivery. Sprockt.com.au the cylinder. But it didn't do it all the time and most of all it shouldn't be possible because the tank is below the level of the carbs. Turns out one of the notorious crappy stupid #$%%$%@! slide clips dropped out already. This ones only 500km old for gawd sake. So that was the cause it looks like, so good so far! See how the outer ones a bit lower then the others.

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'91 Suzuki Across

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Replacing that with another ones fixed it for now. Definitely looking into machining some versions that actually work tho. I read elsewhere that you can polish the needle seats with a cotton bud in a drill with some brasso or wd40. so i did, and it works a treat! make sure to flush out the needle area with some petrol though in case any cottons come loose. Im doing it on the main jet seat here cause i forgot to take the pic while the float was out XD

Oh yeah, and i also read that boiling the carb bowls in lemon juice is a good way to clean the stubborn crud out. One place was quite adamant it would strip everything off instantly. Thats a bit of a lie lol, and i promise that is lemon juice >__>;;

before -

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after -

So no difference there. However it did an ace job of cleaning the inside of the bowls. These were utterly manky before. Made sure i washed them down in water and wd40 to stop the acid eating them away too.

Put the carbs back on and all was well, so time to tackle the damn nut.

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I hoped it would just unbolt from the tank but suzuki in their wisdom decided to mount such a trivial part on with an ungodly amount of rivets.

Didn't have any weld nuts (they're a bit of a wank anyway) so on goes a flanged nut to replace it

A lick-o paint and some new rivets and she's done

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Took two attempts cause i herpderped and rivetting them on without putting the backing plates on. FFUUU

So thats where i am now. Got the Sprocket guide nearly done @Edwardos and the brakes are up next. After a thrash down wisemans of course

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13-10-2011, 08:25 PM

#62

Glen
Rider

Should probably update this as a bit of stress relief SHOCKING DAY... worst in a long long while. Essentially while doing the valve shims i realised the spreadsheet calculator i downloaded was wrong and all the shims were too big by the correct value. So that's $40 down the crapper. And to top off an otherwise fine day i managed to snap one of the cam journal bolts flush while doing the thing up finger tight. That has got to be the wierdest things i've ever seen in my 7 years or so of tinkering. W T F! You can see it in the top right... Going to grab a left hand drill bit and hope to god it

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Join Date: Oct 2010 Posts: 433 Location: NSW Rep Power: 63

comes out. Given how soft the bolt is now and that it came apart while doing it up finger tight gives me a bit of hope. Its definitely not siezed.

'91 Suzuki Across

But to drill the thing out the engine has to come out cause a frame member is in the way. By this point i was livid and manhandled the thing out myself (50kg engine vs 58kg man lol) Boonga-stand (tm) being put to good use -

Now i am a bit worried that all the cam journal bolts are well fatigued on this 79,000km motor. And at nearly $80 to replace them all i just can't afford it. So i was thinking of buying a handful and torquing them all up into a piece of tapped thick aluminium to see if any will snap easily like this one has. Thoughts? But anyway I can't get the drill bit till the weekend so while that's being done i got a friend to help me wedge the gsxr400 into the chassis. Meet the beginnings of the GIXXACROSS! Its a gsxr400 GK71b engine crammed into the across' frame.

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The goal is to basically mock every thing up now and then put the repaired 250 back in for the remainder of my LAMS period, while i properly make the required mounts and pieces and get it engineered properly. I really don't want to live without the boot, cause its the best commuter/utilitarian bike out there, so to give it a bit more poke to keep it interesting when I'm on my opens is the go So far it mostly fits. The chain lines up and the bottom mounts fit. I will have to fabricate a new top rear mount and remake the "cradle" from scratch. Excuse the ratchet straps lol >.> but you can see it does indeed fit within the chassis. Rather better than expected. The exhaust also fits with essentially no modification.

The main unknown at this stage is what to do with the radiators. The engine is a bit longer around the head so the radiator sits farther fowards which i think might not leave it enough clearance when the forks are compressed. So perhaps a pair of

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sidemounted radiators will have to be the go. Not sure just yet, have to look into it But for now the jobs are: 250cc -remove the stuck cam bolt from the 250 -order new shims -get that in working order and reinstall it after a quick clean 400cc -make a temporary cradle as a pattern for the final piece -ditto with the rear mount.

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15-10-2011, 02:57 PM

|
#63

Glen
Rider

Phew. I can finally sleep at night now, The horror cam bolt of doom is removed from its home.

Join Date: Oct 2010 Posts: 433 Location: NSW Rep Power: 63

'91 Suzuki Across

Thanks to my buddy for lending me the $60 left hand carbide drill, it yanked the bolt out in about 5 seconds flat so i didn't have to resort to the ez-fail. PHEW! My new cam bolts should be here monday as well as the correct shims so i can redo the valve clearances and put the 250 engine back in soon. Fingers crossed it makes it run a bit better. Also finished up the template for the rear engine mount of the 400, its just some dodgy 5mm steel plate. The final item will be waterjet out of bisalloy but this at least gives me something to design from

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Thats all for now, next up is to make a cradle template

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