ShammaLamma's GSX250 project

The plan is:
Silver metallic base (also being used without the metal to paint some Norton tanks )
Dusting of black with a lace covering for texture
Blue Metallic
Solid Black metallic final (pinstripes only)

The main colour being the blue and pinstripes of black and silver
Hopefully the colours (not the pattern) comes out somthing like this

 

Thanks,
I found the same thing when I was trying to flush the tank out, there's no position where it will sit and drain easily.
I ended up doing it the hard way, removing all the fittings and shaking it until it was gone.
I think you'd still be ok with a sander, if there was a bit left in it.
Thankfully mine was pretty clean inside when I got it (just a bit of grit ). So I just filled it up and shook it out a few times to clear it.

 

Paint on hold for the moment.
I'm having some issues getting the bike to start can anyone help?
Carbies have been cleaned and floats set. needles and seats are fine
Starter was disassembled and fixed
coils are ok and both spark (LHS strongly and RHS averagely)

But i can still only get the bike to fire once, very infrequently

it improved slightly when i swapped pods to airbox ( that dam fat airbox)
and starting fluid seems to help

but even when turning over for lengthy periods the intake port seems dry ????
(i know it shouldnt be wet but surely not totally dry )

i dont think the pipes are the problem even though there is no muffler


Can anyone help point me in the right direction?

P.S. imo it looks like the engine has never been apart (most of the bike has hardly been touched, except by the weather)
could timing still be an issue???

 

yep fuel in definitely getting to the carbies i undid both drain plugs and it flowed freely

 

Valve clearances and cam marks i can do (tomorow probably)

Compression check: i know it has compression from turning it over manually in gear, but supercheap only sells 14mm+ testers any ideas? (adapter off ebay maybe? i'll check compression last i think)

Any way to check timing without a running bike ? i dont mind getting a strobe light but manual says check at a steady 1500 and 3500 rpm.

Any way to check if coils break down under compression?

Thanks guys, i'd be nowhere without all your help

 

Wow, its been a long time, i got sick of not knowing why it wouldnt start so i shoved it in the shed and forgot about it for a while.
Recently i got the time to get back to it and did what i should have done in the first place and tested compression, wouldnt you know it 0psi both cylinders.

Pulled the head and barrels and the rings were seized to one side of the piston, no seal at all.
i freed up the rings cleaned everything down and Im thinking of re-using the rings. (thoughts?)
The bike only shows 10,000k's on the tach and its pretty clean on the inside so im tempted (+ i can pull it back down once its running fr a while)

Im keen to get it back together this week, does anyone of a place i could get gaskets in melbourne ? (83 gsx250) otherwise eBay will have to do

Wish me luck

p.s. Proof of work

 

Thanks guys

i may have access to a hone but i'll definitely rub it over with some WnD

I gave them a call and it was going to be $70 for just a barrel and head gasket so im going to go with a $50 full set of ebay and just wait it out

 

Finally back together!
Gaskets got here a week early so i got to it today.
Pistons and rings back on after a light pass with some wet and dry
head and cams back on
Coupe of issues i ran into:
Timing marks were all off and the points didnt look much like the manual. but it said the right cylinder should be at TDC to do valve timing, so thats where i set it (rod in plug hole method)
When torquing down the camshaft bearing shell first bolt went fine, a nice click from the wrench, second bolt a horrifying crack, luckily the bolt didnt fully shear so i was able to wind it out, went down to the local hardware store and managed to pick up a nearly identical one for 50c.
(oh and i couldnt resist painting the points cover while i was waiting for the mail )

Tomorow's judgement day, i'll check compression and if its good then it'll go back in the bike with fingers crossed.

P.S. heres a few other pics (http://imgur.com/a/4STBo) if anyone can check out the points unit and see if it matches theirs that would be great

 

IT LIVES!

After putting the engine back in, she ran on start-ya-bastard until it pulled fuel into the carbies and ran beautifully (well kinda)
Threw a new tube into the rear tyre and adjusted the clutch, the first ride isnt far away!

Compression was only 8.5 in the right and 7.5 in the left but i expect that will bump up once the rings re-seat, she's no drag bike anyway

the downside: she died when i unchoked her but it may have been cause she was cold?? i'll have to check again when i have more time

Next comes paint polish, fixing some wiring, new tyres, making a seat and getting an exhaust
Does anyone have experience with the exhausts off we-bike? ive seen one on here but it wasnt running ?
if not, i wonder what it will cost for a short custom 2-1 (i'd like it to be underslung stopping before the rear wheel)

Super excited to continue this project