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Project GSX250 fixer

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

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  1. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Try undoing the clamps all the way if you haven't already
     
    Linkin, Jul 29, 2018
    #21
  2. lawman

    lawman Member

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    I think I totally agree.
     
    lawman, Jul 29, 2018
    #22
  3. Cuda

    Cuda Guest

    They can be an absolute Mare to get on I've struggled with a good few of em over the years (had 7 maybe 8 GSX's) the inlets just go rock hard over time which means you REALLY have to struggle. Have you undone the little 10 millies that hold the airbox in place on either side and moved it back to give you that bit more room to play with? Once you've undone the two ten mills on both sides and moved it back and got your carbs sat in place ready try using a heat gun (dont go too hot) on the inlets to subtle them up again and have a mate there to help you on the other side of the bike to push them home, make sure the tank is off AND there is no petrol anywhere.

    Once fitted 'engine side the inlets on the airbox side can also be an A**e to re seat so again you 'could try using the heat gun to subtle them up a bit but failing that you'll probably struggle like everyone else does I've done this job a few times and still hate doing it.

    Ps, its a GSX250 EZ
     
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    Last edited by a moderator: Jul 30, 2018
    Cuda, Jul 30, 2018
    #23
  4. lawman

    lawman Member

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    Today, thanks to everyone's suggestions I got the carbs on the Suzy just as Hallelujah by Jeff Buckley came on the radio.

    All I can say is "Hallelujah". Air box in on but missing the 3 screws and bolts to hold it in place. Any ideas where I could get said bits without breaking the bank. Lots to do but can't seat the airbox inlets until I have the airbox screwed and bolted into place.

    Thanks 20180802_140134.jpg
     
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    lawman, Aug 2, 2018
    #24
  5. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    To help with the cancer on your engine and covers give it a spray and a rub down with Inox

    inox.jpg
     
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    GreyImport, Aug 2, 2018
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  6. Murdo

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

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    Is there a bearing supply or engineering supply shop in your town?
    Measure the diameter and length (eg 6x20mm) and see if they stock them.
     
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    Murdo, Aug 2, 2018
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  7. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Last edited: Aug 2, 2018
    my67xr, Aug 2, 2018
    #27
  8. Cuda

    Cuda Guest

    If you mean the two little 10 millies that bolt it in place on either side they should be easy enough to get hold of AND they are no more than 1cm long so they don't screw 'through into the airbox 'just long enough to hold it in place.
    If you're missing the two metal sliders that hold the airbox lid on you'll have to order them from somwhere I had to get two for mine as they were missing but as I'm in the UK I can't suggest a place for you but I'm sure someone at your end will be able to.
     
    Cuda, Aug 2, 2018
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  9. lawman

    lawman Member

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    I'm on my way to super cheap this morning.
     
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    lawman, Aug 3, 2018
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  10. lawman

    lawman Member

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    OK so I have the bolts for the airbox and tank. I have the sliders for the airbox but they are way out of alignment.

    I have connected the throttle cable and now need to connect the fuel, vacuum and breather hoses.

    I have the Haynes manual which is not the greatest help so where do all the hoses go. The fuel goes to the outside of the petcock and the vacuum goes to the inside of the petcock. Where do the breathers go? Does the breather from the carb connect to anything as it looks like the breather out the back of the bike connects to the left hand side of the tank.

    Is this right?

    Once I get this all connected properly I will give the engine a good clean.

    Thanks
     
    lawman, Aug 3, 2018
    #30
  11. MarcusG

    MarcusG Meds

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    Hi Lawman,

    I've got a gsx250e. Fuel hose points down, vacuum hose points horizontal to tank. My breather hose just runs under the seat towards back of bike.



     
    MarcusG, Aug 3, 2018
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  12. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    GreyImport, Aug 3, 2018
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  13. lawman

    lawman Member

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    Thanks MarcusG,

    My problem that I can see is that there are 4 hoses coming off the carbs plus the breather going out the back making 5 hoses to connect but the tank only has 3 hose connections. I'm sure that I am missing something.
     
    lawman, Aug 3, 2018
    #33
  14. MarcusG

    MarcusG Meds

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    The extra hoses probably have something to do with the air box. I don't have one and only run 3 hoses. 1 is a vacuum hose and it's only purpose is to allow fuel flow when the bike is running. The second is purely for fuel. The third is for the breather tube and to be honest my bike can run without it but i leave it on anyway.
     
    MarcusG, Aug 3, 2018
    #34
  15. lawman

    lawman Member

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    Next stupid question. I am going to connect the battery but does the positive lead go to the regulator/rectifier? Once I have the battery connected I will put the tank in place and see how that goes. 20180805_113539.jpg
     
    lawman, Aug 5, 2018
    #35
  16. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Look's like it goes on the battery terminal ?
    But don't quote me on it
     
    my67xr, Aug 5, 2018
    #36
  17. lawman

    lawman Member

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    It does not connect to the battery. The battery is already connected and this is a second connector that runs from the positive terminal of the battery and I suspect it goes to the regulator/rectifier but can't tell from the wiring diagram. There is a fuse just after this connector.

    Unfortunately this wire does not quite reach the regulator/rectifier because the terminals on the new battery I bought are on the opposite side to where they were on the old battery.

    I have put petrol in the tank and the starter motor does not turn over but only clicks. Would this be because the regulator/rectifier is not connected. I will have to lengthen this wire and see what happens. I have no idea about these things as this is my first ever go at it.
     
    lawman, Aug 5, 2018
    #37
  18. Murdo

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

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    Doesn't that wire go the the starter solinoid? You may have to check the wiring diagram.
     
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    Murdo, Aug 5, 2018
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  19. lawman

    lawman Member

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    Is the starter solinoid the same as the starter relay in the wiring diagram? I have no idea what either even looks like but I want to learn.
     
    Last edited: Aug 5, 2018
    lawman, Aug 5, 2018
    #39
  20. Cuda

    Cuda Guest

    As Murdo has said that live lead from the battery goes to the starter solenoid/relay .. hope you haven't connected it to anything else and wazzed it over coz if you have you may find you now have problems ..and not fitting the correct battery isn't a good idea either these GSX250's don't have the best electrics to start with so anything that may not be right like a different battery 'may' cause issues ... and if that's the standard reg rec I'd take it off and see how far you can launch it and then fit one off a 250 superdream.
     
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    Cuda, Aug 5, 2018
    #40
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