suzuki across 250 fixup 5

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GSX250F Junker fix up

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05-09-2011, 05:08 PM #61

GlenRider

Join Date: Oct 2010

Posts: 433

Location: NSW

Rep Power: 63

'91 Suzuki Across

Hahah fair enough man

Was hoping to get the brakes donetoday but had to tackle another pair ofproblems i've been putting off till afterthe Ps test. Kinda wish i did it beforecause one of them made the bike anightmare to do the test on. urgh.

First was the constant spark plugfouling on cylinder 4 on a cold start.Seemed to happen at random and theonly thing i could think of was theneedle valve was wedged open, floodingthe cylinder. But it didn't do it all thetime and most of all it shouldn't bepossible 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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29/04/2012http://www.aussiestreetbikes.com/forum/showthread.php?t=11922&page=5


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Replacing that with another ones fixed it for now. Definitely looking into machiningsome 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 needlearea with some petrol though in case any cottons come loose. Im doing it on the mainjet 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 toclean the stubborn crud out. One place was quite adamant it would strip everything offinstantly. 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 wd40to 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 mountsuch 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 toreplace 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 thebacking 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

GlenRider

Should probably update this as a bit of stress relief

SHOCKING DAY... worst in a long long while. Essentially while doing the valve shims irealised the spreadsheet calculator i downloaded was wrong and all the shims were toobig 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 boltsflush while doing the thing up finger tight. That has got to be the wierdest things i'veever 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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6/9

Join Date: Oct 2010

Posts: 433

Location: NSW

Rep Power: 63

'91 Suzuki Across

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

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 vs58kg 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 79,000kmmotor. And at nearly $80 to replace them all i just can't afford it. So i was thinking ofbuying a handful and torquing them all up into a piece of tapped thick aluminium to seeif 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 afriend to help me wedge the gsxr400 into the chassis.

Meet the beginnings of the GIXXACROSS! Its a gsxr400 GK71b engine crammed intothe across' frame.




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The goal is to basically mock every thing up now and then put the repaired 250 back infor the remainder of my LAMS period, while i properly make the required mounts andpieces and get it engineered properly. I really don't want to live without the boot, causeits 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 tofabricate 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 bitlonger around the head so the radiator sits farther fowards which i think might notleave 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 clean400cc-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

GlenRider

Join Date: Oct 2010

Posts: 433

Location: NSW

Rep Power: 63

'91 Suzuki Across

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

Thanks to my buddy for lending me the $60 left hand carbide drill, it yanked the boltout 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 thevalve clearances and put the 250 engine back in soon. Fingers crossed it makes it run abit better.

Also finished up the template for the rear engine mount of the 400, its just some dodgy5mm 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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suzuki across 250 fixup 5

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