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Project Qs GSX250 Cafe Build

Discussion in 'Your 250cc Projects' started by PFAQ, Dec 20, 2015.

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  1. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    The gorilla in the living room is the carburettors. It seems all of the 'cafe' modders want to remove the air box and fit pod filters for aesthetic reasons, which is perfectly understandable. This topic comes up on every one of these threads. CV carbs do not respond well to this. It is best to fit aftermarket carburettors, I always suggest Mikuni VM but unfortunately there are very few people who know how to tune carburettors anymore. Setting idle, slide cutaway and main jet are relatively simple but needle and emulsion tube are much more difficult.

    Rather than build a bike that is almost unrideable, perhaps you could consider using your running bike as a test mule first. Fit a pair of VM Mikunis to it with pods and over time you might be able to get it running well. I suggest using an NGK air-fuel ratio monitor rather than spending a fortune on dyno time that relies on the expertise, or lack thereof, of someone else.
    http://www.ngksparkplugs.com/products/performance-accessories/air-fuel-ratio-monitor
    cheers
    Blair
     
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    Last edited: Dec 24, 2015
    maelstrom, Dec 22, 2015
    #21
  2. PFAQ

    PFAQ Active Member

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    Thanks for the Blair. I have read a few peoples experiences in terms of their headaches dealing with the carburettors. I have something slightly different in my mind. I'm thinking of running Velocity stacks inside a custom airbox that can be fitted and removed without removing the whole motor.
    What are your thoughts on this method? Should way i should be able to tune out the flat spots that people tend to talk about.
     
    PFAQ, Dec 22, 2015
    #22
  3. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    That would seem a reasonable approach. Having both a similar volume and a similar input area as the standard box might be two of the most important issues. Shape is also important, but there is not much room to play with that, and the standard ones just look like they are made to fit the space. I am no expert on these things, but on my links page there are some useful articles on airboxes etc http://www.litetek.co/links.html
    cheers
     
    maelstrom, Dec 22, 2015
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  4. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Speaking of intake length, you mentioned the velocity stacks, I recently came across the variable length setup used on the Porsche 993. You can see it at 16:43 in this video.

    I would really like to make a similar mechanism and try it out. This type of thing is being used on quite a few of the performance bikes these days.
     
    maelstrom, Dec 22, 2015
    #24
  5. PFAQ

    PFAQ Active Member

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    Milestone: finally managed to the engine out. i ended up rolling it out with a tray on the side but the bit that was causing all the trouble was the bracket which sits horizontally along the RH foot peg. Didn't even notice that that was removable......

    [​IMG]

    Motor will be cleaned thoroughly. Not sure if i should paint the outside though..... any thoughts?
    After this is done i will move it on to my mechanic to have a look over the motor as i dont really know anything about these motors; willing to give it a shot though if someone would like to give me a 101 on the basics.


    [​IMG]


    Most importantly; i need to source a new LOOM as i really dont trust this loom at all since its been spliced and what not......lastly one of the missing things from this bike was a CDI module. Something that i will have to track down.

    The big step before i get the frame sandblasted and powdercoated is cutting off the unnecessary tabs. I have put masking tape on the tabs i dont believe i will be needing. Have i missed anything or am i about to remove something important.

    I still have the rear hoop to weld in after i figure out my seating issue and whether i should have room for a passenger.

    [​IMG] [​IMG]
     
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    PFAQ, Dec 22, 2015
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  6. Murdo

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

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    Good work.
    Paint your engine after it comes back from mechanic.
     
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    Murdo, Dec 23, 2015
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  7. Evo

    Evo Well-Known Member

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    Hey @PFAQ i have a couple of spare CDI modules in the shed. PM me if you are interested in in one.

    Good luck with the wiring harness seems to be a common theme in these bikes
     
    Evo, Dec 23, 2015
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  8. PFAQ

    PFAQ Active Member

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    Shaved off all the unnecessary tabs today. Need to go through and clean it up with w grinder.
    There were a fe users who recommended me to kee the original tank and raise it a bit so I got straight in to it.

    Cut off both mounting points under the tank (bracket with the rubber/ bolting point) and attempted to weld one of the brackets I removed earlier.
    Again and again I wasn't penetrating and couldn't figure out why until about an hour had passed..... I had the aluminum wire still feeding...... I was so angry I didn't check that earlier.

    So far it looks okay..... And lines up accordingly. Will weld up the other bracket tomorrow to support the weight of th tank.
     
    PFAQ, Dec 23, 2015
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  9. PFAQ

    PFAQ Active Member

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    SUCCESS!

    Perfect start to the morning. Was hunting for a wiring loom from Suzuki and was advised i need the VIN (should have known this) before they can look it up. Being away from the bike i couldn't get the plate details so i decided to google a part finder for the model of the bike. Located the number and just googled the part number and there it was.....a link to eBay for the exact loom i was after.

    Purchased and now awaiting all the goods to arrive.

    Purchased items
    Wiring loom
    seat
    rear hoop
    headlight brackets
    indicator brackets
    anti gravity compact battery
    clip on handle bars
    handle grips


    other then the usually maintenance parts i believe i have covered everything.
     
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    PFAQ, Dec 24, 2015
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  10. PFAQ

    PFAQ Active Member

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    Question to all. I need to run a rear hoop?
    Would I be able to just cut and not add w rear hoop?
     
    PFAQ, Dec 31, 2015
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  11. Murdo

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

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    So long as you have a cross brace where the top shocks mount it should be ok.
     
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    Murdo, Dec 31, 2015
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  12. PFAQ

    PFAQ Active Member

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    Perfect. The more I look online and stare at the bike in the garage I get more ideas to experiment.
    Waiting in January 4 when workshops recommence work and will be sending the motor off for a leak down and valve clearance test.
    Waiting for a few goodies to arrive to get the final frame mocked up
     
    PFAQ, Dec 31, 2015
    #32
  13. PFAQ

    PFAQ Active Member

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    Just received some new parts in the mail. Managed to also get a CDI from a user on here :D (EVO).

    received the expected news from the mechanic and will need to rebuild the engine. did a leak down test and that pretty much told us everything.

    currently looking for a Full Gasket kit for the motor and my question is; is the GS250TT/TX gaskets compatible to the GSX250?
     
    PFAQ, Jan 11, 2016
    #33
  14. Evo

    Evo Well-Known Member

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    Glad to hear it found you.
     
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    Evo, Jan 11, 2016
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  15. PFAQ

    PFAQ Active Member

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    so the tear down of the motor has begun and already i have hit a few snags.

    managed to snap 2 bolts from the cam cover cap (1 on each cam)
    removed the cylinder head with little problems and then hit a wall when trying to remove the cylinder.

    [​IMG]

    at first class you can tell that the cylinder rings need to be replaced.

    the only thing that comes to mind is getting a screwdriver to wedge between the gasket to remove. are there any other tricks to get the cylinder off as its on there real good!
     
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    PFAQ, Jan 25, 2016
    #35
  16. PFAQ

    PFAQ Active Member

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    Hi All,

    Any ideas where i can locate piston rings?
    Shopped a number of suppliers who stock OEM rings but none have standard.....would it just be better to bore out the cylinder and get 0.5 rings? or is there more to this where i need to replace the piston also?
     
    PFAQ, Jan 25, 2016
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  17. Murdo

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

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    By the amount of carbon in the piston crowns the engine has done a fair bit of work. Try tapping the barrel side to side with a soft face hammer (plastic/rubber) and it should let go. Once you have the pistons free you can them measure them and see if they need to be replaced, or the barrel rebored to next oversize and oversize pistons.
     
    Murdo, Jan 25, 2016
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  18. PFAQ

    PFAQ Active Member

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    It worked!

    Needed to smack it harder. Now that the piston is out I will get the measurements tomorrow and if that's all good then will find a tin of kerosene and wd40 to clean up the Pistons and soak the carbs
     
    PFAQ, Jan 25, 2016
    #38
  19. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    GreyImport, Jan 26, 2016
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  20. PFAQ

    PFAQ Active Member

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    PFAQ, Jan 27, 2016
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