1980 gsx250 project

[ukjules]

Took it for a quick spin today of about 6 miles.
went fine. But hell is it slow ! have not driven a 250 for so long.
Great for cruising though.

Issues:
-Front brake wires - dont know where they go so fb does not work
do they go in the light somewhere ? (I have wiring diagrams but still cannot understand them)
(All other electrics now work, i wish i new how i made them work - more luck)

-Headlight switch on rhs now broke. Tried to glue the light on/off switch and it broke again
other elements of switch work
-Considering zinc plating some items and whether to do myself or find someone near me.
- overall state of electric wiring is terrible (but working)
wish i new more and how to renew bits
-spraying seat base
- need to put on a new seat cover


Needed:
original seat
2 into 2 (twin silencers) for bike

 

[ukjules]

First run out of bike

First run out of bike



First run out with only the foam and no seat base.
Loads to do but it is getting there mechanically.

 

[ukjules]

Carbs balanced today and mixture changed to 1.5 out. (was 2)
Now runs like a dream and revs and idles freely.

2nd swinging arm and seat pan being sprayed today.
Wish i could weld as both my seat pans need welding. they are just saveable.
the foam is perfect.
Need an original type seat cover now or a seat !

-die nut - ordered to thread the seat posts
-rear brake switch ebayed , as other broke
-light switch on handlebar RHS ebayed as internals broke.

electrics still to sort - front brake switch not working and headlight.
I so wish i was better at electrics.

 

[ukjules]

spraying parts today and finished the painting of the seat pan.
It is just usable and firm enough after rust treatment.
Half the securing hooks are rusted off so i have tested spray glue.

I have a cover but for a different model that i will squeeze on for now until i
find a good seat cover.
I will post a picture of the abomination i have created tomorrow.

Swinging arm 3 coats of primer and now 3 coats of base coat. will clearcoat it tomorrow.
then I have a like new swinging arm.

Exhaust:
I realise that if i want a old style 2 into 2 exhaust i am going to have to get one made
especially.
this I will consider in stainless steel. It wil cost and as of yet i know no one who can do it
anywhere.
If anyone knows a exhaust maker let me know ! I simply must have the two into 2 look
and sound. A 2 - 1 on a 250 is ridiculous and sounds awful. Needs to be silent.

Electrics:
I am going to have to ask for help on this.
I am stuck , have problems seeing colours and find electrics impossible.
All i need is the front brake light to work and the headlight !
(Then i need someone to look at the wiring to see the mess i have made to make this happen.)

 

[cloudbreakmd]

Looking good.

 

[1948man]

Good work for sure.

 

[ukjules]

It is now finally ready for an MOT to legally drive on the road.
(Pic of second swinging arm sprayed up and clear coated - came out very well)
Ill swap the one on bike with rust hole in it soon. considering welding it myself and buying a welder ...

I had an issue of it suddenly misfiring and stripped down the carbs ..... again, binned the old fuel (I hadn't done that)
and found one spark plug was coincidentally not firing.

All sorted now and is mechanically sound. (slow though !)
I suppose in 1981 when i was driving these things it seemed fast ?
Desperately need a 2 into 2 exhaust as these 2 into 1's dont work on small 250's i find.
I think that is why it is slow.

Going to have to treat the inside of the tank as slightly rusty and need to spray
the outside of tank.
I found the Suzuki colour code - 05k and the colour is "marble Canadian blue".
( Halfords cannot match this colour unfortunately so need to look elsewhere)
Need to find this spray paint !

some mechanical tuning stats for those people that like this :

- Valves all set within limits
- normal air box - with made to measure foam filter
- Mixture screw 1.75 out
- Cy compression test
Cy1 Cy2
Dry 210 195
Wet 225 (Dont know as forgot to put in the oil )

 

[ukjules]

Pic shows my bodged attempt at putting a seat cover for a 250 Katana gsx .... thing
onto my one. It works but is awful and when i find a new seat or a correct
looking seat cover I will refit it.
Still need to weld up the seat pan.

Now it is mechanically sound in every way , now the work starts to get it
to as it was.

Needed:
2 into 2 exhaust
Seat
Some side panels would not go amiss too.

Question:
The side panels should have black stripes.
Are these striped paint or decal ? Some of the black that is left
on my side panels look like a decal - but might be thick paint.
Need to know to know how to take it off ..... and the expense

 

[Guest]

Decals.

http://www.cmsnl.com/suzuki-gsx400e-1980-t_model13616/partslist/FIG-61.html#results

 

[ukjules]

Nut die:
I bought a m6 nut die to thread the side of seat trip holding posts (as they were totally inaccessible).
they were 6.25mm approx and the nut die worked a treat.
All secure now and the seat can be easily dismantled when i find a
seat cover and to weld the seat pan.

 

[ukjules]

Question:
Do you think the black bit on the side panel right hand side is decal ?
It goes from top to bottom.
(See picture)

We have discovered that the black stripes are decal (mad but true).
These should go in and follow the stripped indentation on picture ...

I am considering a re design and spraying these bits on the other side panel
if I can get the decals off easily. 9I usually can but these seem very gungy)

 

[ukjules]

Big day tomorrow for the old bike !

MOT.
I can barely wait to re create my youth on this old bike !

 

[ukjules]

It passed the mot so is back on the road
BUT
I have a problem.

Currently it runs poorly at higher speeds .... 45 plu ..(ho ho)
(It has only a few weeks ago run ok all the way up the power band so this is a new issue)
When it was running fine i noticed petrol leaking out of the carbs air inlet
when i stopped. to fix this i started looking at the petcock and carbs etc.
I am now at this stage with all ok bar this spluttering at mid range speeeds?


start up and tick over it is absolutely perfect - it sounds spot on.
It as if it is cutting out or running out of petrol above 50mph ? like it does when it
needs to be out on reserve. Or the electrics are cutting out ?

I have taken the carbs off at least 10 times his week to fix this and am completely stumped.

-Valve clearances spot on
-plug gap ok - and a spark on both
-Carbs removed, dismantled and cleaned 3 times now in one week.
Various new bits stuck in.
-Tank removed - chemically cleaned and washed out - petcock not leaking and cleaned out.
-coils checked - both primary - 4.25ohms both sec - 11000 ohms without plug on
- both plug caps ok

what next do you think ? ATU , pick ups ? coils ? carbs ? HELP

 

[Guest]

Hi Jules,

Try and narrow the problem down a bit. Does it happen at a certain rev range or when you reach a certain speed? If it is at a certain speed, what happens when you change down a gear?