1980 GSX250 :-/ Cafe :-)

I'm yet to put them back on the bike, I need some skinny hose clamps to clamp them to the intake manifolds on the head, also need to get an exhaust first. I've got another tank sealing kit to seal the tank and get some fuel in it soon hopefully. I'm using the uni-filter, sock type filters instead of PODS and I'll be playing with tuned length runners etc to get as much mid range as I can.
These little carbies are so simple and from memory very similar/the same as the FZR250 ones I rebuilt a while back.

 

So today I tackled the clutch actuating mechanism, It's basically a giant screw that moves 2 pushrods that release/push the clutch basket, disengaging the unit.
After an hour of fiddling and sorting, I got it ready to test...I rolled the back wheel in gear with the clutch in...it didn't work./ The clutch was not disengaging at all. No worries, I thought, I'll adjust the play etc and it'll work...I was wrong.

Looking at one of the pushrods I noticed it didn't look OEM, turns out it's not. I also found a piece of the OEM rod inside the shaft...turns out it had snapped at some point. No worries, I fashioned up a new one. Still didn't work...Pull the entire clutch assembly apart, only to find two reasons why it's not disengaging.

1. A giant washer that is supposed to be on the shaft the clutch basket slips onto was missing...it was actually under the basket, forcing it to sit incorrectly and out further than it should.

2. My oil pump sprocket was snapped in half. My guess is that the fekking knob who had this thing before me torqued up the basket without aligning the sprocket onto the drive sprocket on the back of the clutch :-( snapping it and then saying to himself...."hmmmmm I might sell this one"

So Off to the wreckers tomorrow to see if I can find something :-(


Also I used some old chair leg filler thingys to finish my custom foot pegs

 

I'm really annoyed. I thought (foolishly) once I get the wiring sorted and my fuel tank finished, I'll be able to get it started ah ah ha ha ha ha oh well, off to the wreckers :-(

 

So I got another sprocket from a wrecker thank god.
Put it all back together, my clutch springs are really soft. I'll replace the clutch and the springs after the first tank of oil

 

Ahhh, That's interesting thanks mate

 

Anybody know a good place for repro decals

 

I literally just want those graphics

But Red, White and Orange, instead of faded pink, orangey white and faded orange ha ha

 

Thanks Murdo!

 

So much has been happening!
Just dropped it off to the exhaust shop to get the headers made, then next week.....IT"S STARTING TIME!!!!!!!!!!!!

 

**UPDATE**

Picked up the bike from the exhaust shop today. Busy day tomorrow, going to try and get it running.
Still got a little bit to do, but the aim is to get it idling, maybe try and go for a quick squirt, but I know my main jets are not going to be big enough.

Also, I was at the local bike shop today in town, they have an Across for sale $500 (it looks pretty shagged)
Also 2 CBR250RR's one is a 1991 and one a 1989, both are in pretty good nick, the '91 model isn't ready for sale yet but they want $2k for the '89, seems a little steep but meh,

Now,.....I want to try and get my hands on the shifter side rear set of a '91 CBR250, I want 2 of them if any body can help me out?
The year isn't such a big deal, but I want the rearset where it is all in one piece, if that makes sense.

I'll keep you all updated tomorrow