1996 Suzuki Across GSX250F

Hi all,

So I got my hands on a cheap GSX250R ($500), was advertised as not running since 2010 - when you turn on the electrics a fuse blows. It has 58000 on the clock.

Had been in a minor accident, top left fairing was knackered and the previous owner got a repaired fairing from the wreckers so he could ride it (until this electrical problem developed).

I got it home, took the fairings off and could clearly see two problems.
1. Positive wire on the right indicator was cut into and was touching the hollow part of the metal shaft.
2. Boot release wires were cut and due to a bad repair job they were touching.

I simply unplugged the indicator and moved the boot release wires, hooked up some jumper leads and away she went! Started pretty quickly and had a tiny bit of smoke (as you would expect for something sitting for 4 years).

I've already repaired the wires for the boot release and have acquired a replacement indicator.

As you will see in the picture(s), the fairing he replaced it with is shocking, not to mention that the top part that the screen attaches to is held together by the mirror bolts and that it's had about 5 big cracks repaired. I ordered another fairing in really good condition yesterday.

The plans for this is to get it back on the road - this will be my first bike.

Some things I've got lined up:
Replace oil + filter. spark plugs, air filter, coolant flush.

I will be changing the colour, at this stage unsure between a nice red or black.

At this stage I'm not sure how worn the rings are, there is a tiny bit of smoke once you back off throttle.
There's also some fluidly type stuff that flies out of the exhaust when you rev it, not sure if that's because it's been sitting or what.

I'll replace the things I said and do a compression test after that to see where I'm at.

It idles and revs fine, no bogging.

Anyone suggest to check anything else or do anything else? Clean carbs?

Cheers - Matt.

 

Bit of an updated - have mainly been cleaning the chassis up but have dumped the oil, coolant and fuel, changed the plugs.
Battery, oil filter, air filter and top left fairing are on order.

Have sanded back all of fairings apart from the top left (on order). Will be primed and painted shortly - colour of choice is black (after seeing this I was decided: http://s368.photobucket.com/user/TUFF4D/media/IMG_0458.jpg.html ).

Question - does anyone know what these wires are for (yellow green)? It's one of two which are floating about.

 

Discovered that those wires run straight to the clutch switch, my question is now - what's supposed to be connected to those wires as there are no other wires to plugin to around that area.

My only other loose wire is the fuel lid switch, might try find another switch that fits in the cutout of that panel so it doesn't cost me an arm and leg to replace.


Have painted the exhaust with high temp paint, will probably melt off the headers but at least it looks pretty for now.


Painted rear panel and indicator bases


Some snaps of the chassis (don't mind the magneto cover, was scratched and I'm in the process of sanding to be painted)

 

Yeah will do

 

The top left fairing arrived today, had a few deep scratches so some parts have been sanded back to plastic. Doesn't really matter because everything will be primed.

Have repaired 3 cracks on one of the rear fairings with Q-Bond, that stuff is amazing but costs a fair bit if you don't have any (~$60 a box).



Thanks @GreyImport for suggesting the Steelo Soap Pads - done the job!

 

Okay so my oil filter arrived today - filled up oil and bolted the exhaust back on.

Took ages to start - I have a cylinder (or two) which are not firing (I think only one (see below)).

I'm not sure of the cylinder numbering but, I done the water squirt test on the headers

Looking at the headers from the front of the bike
4 3 2 1 - (may not be correct order but can help you identify which cylinder the water didn't dry up on)
4 3* 2 1 - *cylinder the water didn't dry up on

Have pulled out the plug on number 3 and grounded the outside - sparks fine.
What else do/can I test?

Possible I got the coils in the wrong order? Going to have a look at the resources and see how I go, in the meantime if anyone has any suggestions, let me hear them!

Here's a video, stalls on low revs at the moment:
https://plus.google.com/+MattCincot...6100787985603352994&oid=118353291573823499684

 

Sorted! Had the leads for 3 and 4 mixed up. Pity it's a bit late now

 

Went for a small 24km ride tonight around the block, over and over again - it's running great!

Guess now it's just waiting for the fairings to get painted. I also ordered some Suzuki outline decals to go on the boot and on one of the rear panels.

Will add some new tyres and brake pads to the shopping list, but I need to fix my car first (done the rear main on the weekend).

 

Fitted the fairings again today, noticed some panels that don't line up.

Going to try get another bracket that holds the headlight, speedo, indicators etc. I don't think the indicators are supposed to be pointing inwards so much, and the headlight doesn't line up.
It was obviously dropped or something on the left side (the fairing that was screwed), so just need to get everything lining up again.

As for the top right fairing, I've got no idea what's going on, maybe something under the boot is holding it up, otherwise there's a bracket at the mid point which might be bent.

Car didn't do a rear main - shot a rivet through the bell housing - so that's going to delay this a bit.

 

I'll try re-fit the boot tonight, I have a feeling I moved the wiring loom so that it's in the way of the boot sitting flush.
As for the headlight bracket, I've called up a few wreckers but there's a guy in Vic who has a couple, so hopefully one of those is straighter than what I've got.

Thanks for the suggestions @Phil ! Much appreciated.