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Project GSX250 fixer

Discussion in 'Your 250cc Projects' started by lawman, Jul 22, 2018.

  1. lawman

    lawman Member Premium Member

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    Hi all,
    I have been given what I believe to be a 1982 Suzuki GSX250E. Would be happy if someone knows the exact model. It had been in a garage under cover for the last 5 years. It is all there and original with no modifications at all. The engine was stuck but I have been able to free it. The carbs had been removed and I have to clean and replace them. Tank is clean inside and all gears operate and the clutch feels fine. I am not very mechanical so will have lots of questions on the way forward especially about servicing the brakes.

    Thanks

    Frank 20180722_100057.jpg 20180722_100105.jpg 20180722_100159.jpg 20180722_100057.jpg 20180722_100105.jpg
     
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  2. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Welcome, if possible get yourself a genuine factory service manual and start reading. Then make a plan to do every step in the service section. When you hit any problems the friendly people on this forum can help out.
    Cheers
    Blair
     
  3. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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  4. lawman

    lawman Member Premium Member

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    Thanks for the info. The bike is going to be a rider not show.
     
  5. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Welcome, nice pick up. Any questions (no matter how silly/mundane you think they are) will be answered to the best of our collective knowledge.
     
  6. TonyZXR

    TonyZXR Active Member Premium Member

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  7. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Welcome to the forum
     
  8. Andych

    Andych Well-Known Member Premium Member

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  9. lawman

    lawman Member Premium Member

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    Will start cleaning the carbs today. What is the best way to clean them inside and out? 20180721_091827.jpg
     
  10. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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  11. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Remove the bowls and diaphrams, clean all jets in 3 bond engine conditioner or thinners, blow through all passages with compressed air, wash all in petrol and carefully assemble.
    Pay particular attention to the idle jet and passages as being so small any little bit of crud will block them. No need to touch the butterflies, just clean around them with an old toothbrush and I would also keep the two carbs together not disturbing the shafts or seals. Don't forget to clean the tap and tank so you don't get more crap into your freshly cleaned carbs. Maybe fit an inline paper type filter as well.
     
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  12. lawman

    lawman Member Premium Member

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    Thanks for that. I have lots to do.
     
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  13. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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    Be gentle with the jets when removing as they are brass and can be 'soft' and obviously stuck hard in place initially ... especially the pilot jet

    gsx carb.png
     
  14. lawman

    lawman Member Premium Member

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    Decided to hand the carbs to a friend that knows what they are doing. Much safer that way.
     
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  15. lawman

    lawman Member Premium Member

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    Carbs are now cleaned and I have been trying to get them back on the cylinder heads without success. I don't have the strength that I used to have due to a recent operation so is there a trick to getting them back onto the bike. Any ideas at all would be good.

    Thanks
     
  16. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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    Use rubber grease on the inside of the rubber intake boots

    rubber grease sml.jpg
     
  17. lawman

    lawman Member Premium Member

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    I surely will give it a go so thanks a million.
     
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  18. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Heat the rubbers gently with a hot air gun to soften them.
     
  19. lawman

    lawman Member Premium Member

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    Well I still can't get the carbs to go on the bike and I have used rubber grease, heat, hammers, pinch bars, very sore hands and nothing is working. I hate to think what this has done to the insides of the carbs. I think my biggest problem is that it is a 2 person job.
     
  20. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Sound's like you'll need some new manifold rubber's then
     

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