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Project Kawasaki EL250

Discussion in 'Your 250cc Projects' started by murdman87, Aug 25, 2019.

  1. murdman87

    murdman87 Well-Known Member

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    My Bike:
    96 Suzuki Across
    New fuel lid arrived.
    2 problems.
    Firstly, key is a different profile, so I can't rekey it to take the bike key.
    Secondly, it doesn't actually close on the tank. It has a slightly different profile.
    Original lid had one moving part, this one has two, and seems too shallow to catch the latch.

    Problems are starting to mount up with this old thing. And finding parts is proving difficult.
     
  2. Murdo

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

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    1937 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, FT500 plus a few others.
    I heated the boots and stretched them, then super glued into the airbox and with some more heat from a heat gun to soften just the carb ends to push onto the carbs and hold whilst doing the clamps up.
     
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  3. murdman87

    murdman87 Well-Known Member

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    The terrible paint was hiding a lot of bog on the tank.
    20200509_135640.jpg
    For those more experienced than me, do I bog first then prime it, or primer then bog?
    Don't think I have the skills to try and pull the dent out at all.
     
  4. Murdo

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

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    Can you get a tyre lever or a flat bar through the tank cap hole and push some of that dent out? Then grind the surface with a rough disc and apply filler, then primer.
     
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  5. murdman87

    murdman87 Well-Known Member

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    I'll give it a go.
    Thank you.
     
  6. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    I have seen Inner tubes used to pop dents out of tanks as well.. or find a mate who has spent $30 on a cheap eBay PDR kit.. you would be surprised at how much of that dent you could get out... and the less bog the better.
     
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  7. mpouk

    mpouk Member

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    My Bike:
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    I uploaded for anyone who wants the service manual el 250
     
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  8. Parker briggs

    Parker briggs Member

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    My Bike:
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    Hey so I've had my 91 el250 apart for a while now and forgot how to reconnect the fuel lines, is there a diagram in the service manual or can you send me a pic of the hose connections?
     

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