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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. Aaron81

    Aaron81 Active Member

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    Mate firstly, thank you very much I have been racking my brain for the name of the battery you have just mentioned as I have been trying to find them for quite some time now so cheers mate,
    Secondly the car you have done is a real beaut too well done :)
    Third, my hat goes off to you man it sounds like you know what you want to achieve by the end of the day and aren't afraid of getting your hands dirty.
    Having owned one of these I always loved the simplicity of the original design and watching how you are tackling the customizing of the bike I am very interested in seeing the outcome, especially with the use of the velocity stacks as mentioned before.
    Personally as far as the head goes seeing the build up and the age of the motor I would probably do a hone and bore and go oversize, have you got a direction with the headers yet or is that still in the design stages?
     
    Aaron81, Jan 27, 2016
    #41
  2. PFAQ

    PFAQ Active Member

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    Hi Aaron,

    heres the link the battery if you want to purchase. They have some cool bits and pieces too.

    http://www.shop.modernmotorcyclecompany.com.au

    I think you are giving way too much credit especially with the quality of the builds on this forum; nonetheless thank you :D
    I've been looking at bike designs everyday and have a good idea of what I'm after (accomplishing it is the hard part). I will definitely look at going a size larger if my pistons and require replacements as its very hard to find replacement rings atm.
    The headers is still in the works but i would be leaning towards unequal length 2-1 headers just so i can get a nice boxer like rumble from the bike. See how the motor goes before i start planning big.

    In the mean time i have decided to get my stock GSX250 registered and club registered just so i can enjoy the bike.

    TO ALL: has anyone had any issues with the GSX250 stand scraping the floor on cornering? I'm probably 74kg so weight shouldn't be an issue.....
     
    PFAQ, Jan 27, 2016
    #42
  3. Phil

    Phil Senior Member Contributing Member

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    It all depends on how you take the corner I guess. The higher the speed the greater the angle...and so on.
     
    Phil, Jan 27, 2016
    #43
  4. PFAQ

    PFAQ Active Member

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    That's the problem, I'm not even cornering that fast....... Probably 15km?
     
    PFAQ, Jan 27, 2016
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  5. PFAQ

    PFAQ Active Member

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    UPDATE:

    Managed to get some time to myself in the garage on the weekend. Finally got my rear hoop delivered in the correct size (ordered previously without measuring the bike...) and on it went. Measured it up and kept what i could of the original frame.
    Welds are definitely not the prettiest but they definitely hold.

    [​IMG]

    Throughout this build i have been haranguing my neighbour about what he has previously did to use GSX. i didn't really want to cut the centre support to fit the electrical tray so i improvised and decided to let everything be exposed from the bottom. Because i decided to go this route i made another problem for myself being the loom placement.....
    I needed to elevate my seat a little at the front to run the loom through and then place where i would run my electronics underneath. i will need make a hole in order to feed the wire in from the top.

    next up is to finalise all the electronics and wiring and then off it goes to sandblasting and powder coating.
    Is there any problems with mounting these at the bottom being exposed?

    [​IMG]
     
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    PFAQ, Feb 1, 2016
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  6. Murdo

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

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    Good idea with the punched metal racking. Will give a bit extra strength to the frame without much added weight.
    Those units should be fully sealed, so no problems. Would suggest you put some electronic grease (white stuff) on the connectors at final assembly.
     
    Murdo, Feb 1, 2016
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  7. PFAQ

    PFAQ Active Member

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    definitely will do.
     
    PFAQ, Feb 1, 2016
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  8. PFAQ

    PFAQ Active Member

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    I was working on the bike today running the wires through to make the final cuts and realised that I have a gsx250t wiring loom (36610-11410)
    Can I get access to the manuals as I need to cut the plug and wire the right hand side ignition, light and kill switch?

    I will also need to either custom wire my CDI (unlikely as it's missing the plug) or buy a second hand one from the states (32900-47020).

    Created a new battery mounting plate to hold it up underneath my tray.
    Need to finalise this wiring before I can move forward
     
    PFAQ, Feb 1, 2016
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  9. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    GreyImport, Feb 1, 2016
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  10. PFAQ

    PFAQ Active Member

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    With this flasher relay; how do i test it or do i just test for continuity?
    Any recommendations for replacements? smaller the better. the standard one is a block which is $30 or so but i dont know the real importance of going OEM.

    [​IMG]

    Battery tray to mount on underneath. fitted it and looks good so far.

    [​IMG]
     
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    PFAQ, Feb 1, 2016
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  11. PFAQ

    PFAQ Active Member

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    PFAQ, Feb 1, 2016
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  12. Murdo

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

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    Murdo, Feb 2, 2016
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  13. Evo

    Evo Well-Known Member

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    Continuity will not tell you much. You need to pull in the coil. To test you will need to put + and - to the correct pins and test the output through a load(indicator). Personally I wouldn't worry bout OEM. Plenty out there for a lot less. I got mine from thirdgear.com.au under $10.
     
    Evo, Feb 2, 2016
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  14. Evo

    Evo Well-Known Member

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    Show a pic of your CDI and your loom. I'm sure that you be able to make up a plug are some form of adaptor
     
    Evo, Feb 2, 2016
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  15. PFAQ

    PFAQ Active Member

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    will get a photo today once i get home. but its the same one that i received from you previously.
    that or i get a plug and play one from online for $200 or so.
     
    PFAQ, Feb 2, 2016
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  16. PFAQ

    PFAQ Active Member

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    IMG_3398.jpg Been looking at the wiring diagram and can't figure out what this plug is. I believe it is connection 8
     
    PFAQ, Feb 2, 2016
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  17. PFAQ

    PFAQ Active Member

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    Also I've been scratching my head trying to find out where this rectifier came from but can't figure it out. No branding or numbers.

    Either way I need to wire it up to my bike.
    I have 6 wires available and only need 5 according To the wiring diagram (wiring diagram - gsx250ez (UK) model)

    Black/white
    Red
    White/red
    Yellow
    White/blue



    Same can also be said for the CDI where the diagram indicates I need 3 wires.......

    View attachment 18390 View attachment 18391 View attachment 18392 View attachment 18393
     

    Attached Files:

    Last edited by a moderator: Feb 3, 2016
    PFAQ, Feb 2, 2016
    #57
  18. Clancy1

    Clancy1 Well-Known Member

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    The plug you're holding looks like the plug for the cdi box. Orange/white goes to your RH switch block and is part of the killswitch circuit. That rec/reg doesn't look standard either.
     
    Clancy1, Feb 3, 2016
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  19. PFAQ

    PFAQ Active Member

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    based on the diagram my CDI(igniter) only has cables.
     
    PFAQ, Feb 3, 2016
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  20. Clancy1

    Clancy1 Well-Known Member

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    the CDI should be plugged into the coils and the ATU (Automatic timing unit) via one or two plugs from memory
    I'll take a photo of mine for you if I remember.
     
    Clancy1, Feb 3, 2016
    #60
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