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Solved GSXR250 - Brown chunks caught in oil strainer?!

Discussion in 'Maintenance' started by Zippy, Mar 1, 2021.

  1. Zippy

    Zippy Active Member Premium Member

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    Hi all

    Would be grateful for the advice of more experienced members!

    With the oil pan still removed from my GSXR250, I noticed something caught by the mesh of the oil strainer.

    5.jpg
    4.jpg



    So I removed the strainer, shook it about, and this is what came out...

    2.jpg

    :lolsign:


    Other than the above, the oil pan was pretty clean with no other debris to report.

    At first I thought these brown chunks were oil that solidified within the oil strainer, because some of the edges seem to have a rounded form to them.

    But after a bit or research, perhaps they are pieces of plastic timing chain guide?

    Would be grateful to get your views on:

    1. What you think the pieces are?
    2. What you would do next?


    :D
     
  2. Linkin

    Linkin The Apprentice Premium Member Contributing Member Dirty Wheel Club

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    Given the colour and texture, I would hazard a guess that it's chunks of insulation from the stator. Second best guess would from timing chain guides, but they are usually black in colour
     
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  3. CobraBaz

    CobraBaz Active Member Premium Member

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    Interested in this as when i dumped the oil on my engines gj73a and gj74a both in same tub :( i transferd to another tub i did find a small piece of plastic exact same as the brown stuff,,,, jus not sure which it from :(
     
  4. Murdo

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

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    Looks to be stator insulation. Is it charging ok? If it is then don't worry and ride it.
     
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  5. CobraBaz

    CobraBaz Active Member Premium Member

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    i thought the same didnt think anything plastic would be major lol,,, although i woud like to know where it came from,,, my bits are identical jus unsure which bike its from lol
     
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  6. Zippy

    Zippy Active Member Premium Member

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    Thanks for the tips Linkin and Murdo!

    Your suggestions helped me find a photo online from a GJ72a which shows very similar looking plastic pieces behind the generator cover:

    Untitled.jpg


    Also it's reassuring to hear I'm not the only one who's found this CobraBaz.
    If yours was ok after you kept riding it, I might do the same.

    That's a good question... Which I can't answer as I haven't actually ridden the bloody thing yet! :headbang:
    Something to bear in mind and test when it's back on the road though.


    Seeing as the bike is currently sitting dry with the sump off, would it be worth taking the cover off and seeing what else is floating around in there? (assuming a just un-doing a few bolts)

    Or is this unnecessary / asking for trouble?!
     
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  7. CobraBaz

    CobraBaz Active Member Premium Member

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    gota pop the generator cover off mine to replace gasket today so will check mine to ill get a pic,,,,,,,
    just be carful ya dont rip gasket when removing then you can refit :)
    Ive not test rode my bike yet other than 300 yard up the road and back,,, been laid up for 12 year untill last week :)
     
  8. CobraBaz

    CobraBaz Active Member Premium Member

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    thumbnail_DSCF0292.jpg thumbnail_DSCF0291.jpg thumbnail_DSCF0290.jpg thumbnail_DSCF0289.jpg

    theres a pic of my flywheel that the breakers sent me before i bought the engine,,,, wanted to check flywheel magnets for cracks,,, the pic you posted has cracked magnets,,,, it would be worth popin your cover off just to check condition of the magnets, from what i have learned they are known for cracking ,,, white lines down centre of them are stress marks where they due to crack,,,, if they are cracked and come off,,, will wreck stator ect,,,,, the plastic looks as said so wouldnt worry about that,,,
     
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  9. Zippy

    Zippy Active Member Premium Member

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    What a happy coincidence! Would be very interested to see what you find.

    If the generator cover gasket is anything like the sump gasket I removed, after 34 years it will be toast.

    Having learned how hard it is to find some of the parts for these bikes, I'm now in the habit of finding replacements before I break anything!

    Not sure about the specifics for the Cobra, but the GJ72a and GJ73a part numbers are the same: 11483-05C00 (apparently now replaced by 11483-11D00), which Fowlers Parts have for £11.


    If mine's off the road that long I'm setting fire to it. :minigun:
     
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  10. CobraBaz

    CobraBaz Active Member Premium Member

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    if you look close at one of the pics i posted you can see white lines on the flywheel magnets,,, i will be replacing it once bike up and running propper,,, that is the reason i changed my engine as my flywheel was damaged, and cant get replacement flywheel for gj73a engine so after help off here i swapped bottom end for gj74a, as the flywheel are easy to get ,,,
    Cobra is just Naked version of gsxr250rk 1989,

    https://www.2fiftycc.com/index.php?...-other-problems-now-running-with-video.11288/
    check my post,,, i was quite a novice before i joined here,,, ive learned lots about my bike with help from this site m8
     
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  11. CobraBaz

    CobraBaz Active Member Premium Member

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    Popped my new gasket on today and got pics of plastic bits ,,,,

    IMG_20210303_122444.jpg IMG_20210303_122602.jpg
     
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    Last edited by a moderator: Mar 4, 2021
  12. Zippy

    Zippy Active Member Premium Member

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    Awesome, that's a great photo, thanks Cobrabaz!

    That is clearly the source of the plastic particles that found their way into my oil strainer.

    I will remove the same cover from my bike tomorrow to see how much more is floating around and whether there's any left in place! :aggressive:
     
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  13. CobraBaz

    CobraBaz Active Member Premium Member

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    check the magnets for cracks or signs of cracking, the white lines on mine is what i believe is the first signs of them going,,, still some life left in mine yet but i will inspect regular ,,,, save you lots of hassle to look before anythin could happen!!
     
  14. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    Re epoxy the magnets now before they detach totally and cause $$$$ damage with the engine running..they go when at high revs and it will happen in short order :) good find at the right time :)
     
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  15. Zippy

    Zippy Active Member Premium Member

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    Took the generator cover off yesterday...

    missing insulation.jpg

    There was a distinct lack of insulation around the stator, with what remained looking very similar to what was caught by the oil strainer.

    So well spotted Murdo and Linkin and thanks for your advice.
    Thread topic now updated to 'Solved'!

    Interesting how when searching for a replacement part no. 31402-05C00, the insulation is a different colour:

    stator new.jpg
    I wonder if it's better!



    Moving on to the state of the magnets...

    crack1.jpg

    crack2.jpg

    There are a couple of cracks already formed.

    What's the procedure Simon, add some high-temperature sealant to the crack directly and around the base of the damaged magnets?

    Try and get a replacement stator because it's only a matter of time before this one detonates?

    Would TIG welding the cracks be a stronger alternative?

    Best just to get another bike?!

    :commando:
     
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    Last edited: Mar 8, 2021
  16. CobraBaz

    CobraBaz Active Member Premium Member

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    I bough my engine knowing the condition of magnets,,,, i gona put some more resin on them and keep a check on em, but will replace the flywheel in next few month or when they start to go more,,, about 250 quid i think,,,
    What bike is it m8?
    Good that you found now m8 :)
     
  17. Zippy

    Zippy Active Member Premium Member

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    Ok well nobody has said to get another bike, so I'll continue with this one for the time being. :)

    It's a GSXR250 (GJ72a), CobraBaz. You're right, I think a replacement 'rotor assembly' (31402-05C00 as shown in a previous post) is around £300.

    To answer my previous question, I think welding isn't mentioned much in relation to this fix because it could interfere with the strength of the magnets.

    Didn't realise that stator magnet movement was such a common thing until reading some other forums about the Suzuki SV...
    Using the search terms 'JB weld stator magnets' brings up quite a few threads!

    As helpfully suggested in this thread, I'll put some heat and oil resistant epoxy glue around the magnets (in place of the original insulation that disappeared into the oil strainer) to reduce the chance of the cracked magnets coming loose. I'll then check that everything is charging ok once the bike is back together and see how it holds up over time.

    :thumb_ups:
     
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    Last edited: Mar 9, 2021
  18. CobraBaz

    CobraBaz Active Member Premium Member

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  19. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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  20. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    No bike replacement needed lol :). Make a template to go around two magnets with a protusion inbetween donating the difference they are apart. Mark the start/end of each. Template is easy with soft wood. What your looking for is to keep the distance of the magnets the same (where they are currently). You will need this as they will move when you replace them and sometimes as the epoxy sets. Spray a glue remover (tar and glue solvent will work fine) and leave overnight. Heat up the outside of the casing mildly (any heatgun) so its hot to tough but not red hot, I use a milwaukee battery operated one, thirty seconds is fine. Reapply solvent and do this a few times. Gently lever the magnet off. Clean the area with solvent. Re apply epoxy and reattach. Magnets are a common part across many models - I can't see an issue with replacing any damaged or failing ones if you have suitable donor parts providing the wxdxh measurements and polarity are kept the same m8
     
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