Info Ade's 1988 Suzuki GSXR250RR

Oh-noooooooo............

Ive made a School-Boy error!..........forgetting that the bike has just sat for 16 years....I put the front end back together, without checking the fork stem seals....and guess what?....one is leaking badly!

Oh well, back off it comes.

I managed to fit the carbs and exhaust this evening.

 

Onwards and upwards, I love my parts cleaner & shot blaster......sorry about photo quality of the first few shots....there was a Booger on the lens ;-)

 

That's enough for one day......30 hours this weekend.....getting there. the engine turns on the starter button. still plenty to do, rain has stopped play for today.....

 

Oil Filter change this evening, the old filter wasn't too bad for 16 years old. oil was black. I also read the 'Handbook' and noticed there is a 'Prime' setting on the fuel tap, to allow filling of the carbs without cranking the engine over to generate a vacuum to allow fuel flow.

I'm glad I found this out as it will be useful. Only yesterday, I was reading another thread from another member, who was having trouble with a fuel tap not working, and not working even on 'Prime'. I was just wondering if the chap knew to remove the small screw whilst turning the tap to the Prime setting. not sure if his bike had the little screw to adjust.

 

Well......a quick up-date......I filled the engine with fresh oil, then cranked it for a bit to circulate it through all the oil ways and bores, then i installed the rad & fan assembly...wired everything up, charged the new Battery & installed it, making new battery leads, as some of you will remember the corroded state of the old ones.

I filled the tank with a little fresh petrol, set the fuel tap (pet cock) to prime, checked that the fuel bowls were full.....then ignition on....and cranked it.

After a bit of fiddling and adjusting and playing with the choke......SHE ONLY SPLUTTERED INTO LIFE!!!!!

I am so happy I could cry....(not literally...being a bloke and all lol) I topped up the oil, set the tick over adjuster, and give her a bit of throttle....I let her tick-over for a few mins, checking all joints and seals, there is a possible oil leak (will see better tomorrow).

The carbs need Balancing, but she revs good enough, I can tell not all are lifting together. she revved cleanly after a few mins, I took her up to 11k and by crikey she sounds great.

Still lots to do...I need to get the brake lines installed, chain fitted and adjusted, front sprocket housing fitted with the new clutch cable. I want to get it somewhere close so I can actually ride it, so I can get it to my friend who can balance the carbs with his digital balancer, and check it over, just to make sure the diaphragms' are not leaking etc...

PHEW! im so relieved she runs.....ive spent a lot of time on this project....but its been worth it. I will post a vid to youtube soon so you can hear 'Baby Flash' Thanks everyone for your kind comments and assistance, much appreciated.

It's not finished by a long way....keep watching

 

Loving every second.....

 

Some issues, I need to balance the carbs...that goes without saying, but its got starting issues, unless it starts right away.....it stops firing and just cranks over. I can leave it for 10 mins, then try to start it again, it fires and really tries, then just crankes again, and I have to leave it a while again.

It sounds like a fuel issue, its as if the fuel slowly trickle's into the carbs and after a time there is enough to start it.

Question. Can I disable the tank vacuum system? so its just a normal system.

 

Thanks Phil, this is the reason i asked. it only runs on prime. It won't run on any other setting. I was looking to buy a 'standard' aftermarket fuel tap (non vaccum type with reserve) at least i could tell fuel was low and not empty.

Another reason I'm thinking of changing the fuel tap is that i had to change the carbs, as the original ones were totally shot. The original ones used the vacuum system, the replacement carbs didn't.

Instead of the vacuum hose teeing off from between the carbs up to the fuel tank, the new carbs didn't have a T piece, just a pipe linking the two carbs together.

Was this setup correct for the later model gsxr250 GJ73A?

 

The fuel tap saga is resolved, it works as it should do now on vacuum, I also fitted a new H/D chain. it was my first time with a riveted chain, the tool was easy enough to use. here are a few pictures.....

I'm having a bit of trouble with the engine....it doesn't want to start again after its been warmed up....any ideas? also ive found out that the clutch is seized.....so it just stalls when put in gear....so it's off with the clutch housing tomorrow.

 

It just cranks when hot. No matter how much throttle is applied. Always starts on the button from cold with no choke. So i guess i need to wind in the 4 mixture screws half a turn. They are all out 2.5 turns

 

Thanks Bud, I will do a FULL turn in on all four carbs and see how it runs a bit later. got to drain the oil and get the clutch housing off and assess the clutch 'stuck-closed' situation, I guess that being sat for 16 years it would 'Glue' together.