Questions re: 1988 Suzuki NZ250S

[Chalmes]

Hi there. First post for me as I just bought and started pulling apart my first bike yesterday.
235677

I am in the process of sourcing a service manual for it (in Japanese which thankfully my partner can read) but until then I have a few questions.

1) I took the instrument cluster off to get me access to the locking mechanism (its completely worn out and can be turned with anything) and noticed that the cable leading to the speedo is completing dry (if anything, started to rust) The cable leading to the rev counter is nice and lubed, and I assume they should both be the same?
235676

2) The air filter is non existant......it had perished with what appears to be fuel. I'm going to pull the carb out and clean it where it needs it.......but what does a new air filter for the bike actually look like? Should I be able to remove the mesh screen that can be seen in the picture? Also, there seems to be only 1 trumpet leading into the airbox, with another hole there that appears to have originally held another. Also, the trumpet is facing BACKWARDS so if anything at speed it would be getting a vaccum instead of having air blowing into it. I assume that the trumpets are in fact supposed to face forwards?
235675

3) The "Pass" switch on the left handlebar has been...shall we say....rewired somewhat and now no longer has any function. By the looks of the original wiring it was used to flash the highbeams on? Does this sound about right?

Cheers in advance.

Jon

[Chalmes]

And a couple more questions :)

4) Can the airbox be removed form the frame without removing the engine? It appears to have a wider part at the base that wants to keep it in place...but maybe theres a trick to it?

5) To remove the exhaust from the head, do I unbolt the retaining plates and then carefully lever the exhausts out form the head? Even with copious amounts of crc in there it seems to be pretty stuck.

Thanks again.

Jon

[onearmedbandit]

Sorry can't answer the NZ250 specific questions but,

1/ Yes ideally it should be lubed.
2/
3/ It is there to simply flash your high beams.
4/
5/ Yes unbolt exhaust from cylinder head, and also from anywhere else it's attached. (not necessary but makes it easier.)

[Conquiztador]

10 chars..
Hi there. First post for me as I just bought and started pulling apart my first bike yesterday.
235677

You have just bought the following:
- A Suzuki, useless fucks on providing parts in NZ. But will not make a difference to you as the NZ250 has no parts anymore. Only option is improvise (find bits that fit) or get s/h ones (buy another bike for spares.
- One of the best 250cc bikes ever made. Single cylinder, oil/air cooled, light, fast and economical. (We had ours doing 180k/h)
- The S model (front faering) that is a little cooler than the standard.

I am in the process of sourcing a service manual for it (in Japanese which thankfully my partner can read) but until then I have a few questions.

A: There is english ones. I had one but gave it away with the 4 bikes when I sold them. Ask on here and on TM and you will find one or get someone to copy one for ya for a dollar or two.


1) I took the instrument cluster off to get me access to the locking mechanism (its completely worn out and can be turned with anything) and noticed that the cable leading to the speedo is completing dry (if anything, started to rust) The cable leading to the rev counter is nice and lubed, and I assume they should both be the same?
235676

Do tey work? ( spin and feel if it is easy or hard work) If does not spin easily go to someone who can make cables as you will not find new ones in stock. But if you take my initial advise and buy a spares bike you be fine.

2) The air filter is non existant......it had perished with what appears to be fuel. I'm going to pull the carb out and clean it where it needs it.......but what does a new air filter for the bike actually look like? Should I be able to remove the mesh screen that can be seen in the picture? Also, there seems to be only 1 trumpet leading into the airbox, with another hole there that appears to have originally held another. Also, the trumpet is facing BACKWARDS so if anything at speed it would be getting a vaccum instead of having air blowing into it. I assume that the trumpets are in fact supposed to face forwards?
235675

Go to a bike shop. Buy any MX (motocross) air filter that is same size and you be fine. She only has one carby so any extra holes need to be covered.

The "trumpet" is supposed to face backwards. We are not talking about a supercharger, just a carbi that will suck in the air it needs.

3) The "Pass" switch on the left handlebar has been...shall we say....rewired somewhat and now no longer has any function. By the looks of the original wiring it was used to flash the highbeams on? Does this sound about right?

A: Yes, it is a "flash the headlight" switch. U will not need for WOF (or when U ride) just forget it.

4) Can the airbox be removed form the frame without removing the engine? It appears to have a wider part at the base that wants to keep it in place...but maybe theres a trick to it?
A: Why do you want to remove airbox? Carbi comes off, filter comes off, and the box stays.

5) To remove the exhaust from the head, do I unbolt the retaining plates and then carefully lever the exhausts out form the head? Even with copious amounts of crc in there it seems to be pretty stuck.
A: Muffler off, bolts off and pipe will come out. No secret squirrel stuff.



Cheers in advance.

Jon

[Conquiztador]

Now I get it!!! This is the $1,1K one that was on TM just a few days ago!! (Recognised the tank) Good buy!

A couple of things to watch:
- Tank is crap in seams and might leak. Get some tank sealer (stuff ya pour inside, splash around and leave to dry) and it wont become a problem.
- CDI unit is on r/h side under seat just behind tank. It has a tendency to be affected by rain and petrol if tank leaks. You will notice when bike starts to missfire for no reason.
- Conrod can stretch if used at high revs for heaps of times. (You will notice when there is a ticking sound when valves hit piston) Easiest option is to add a head gasket. Not the "official" fix, but as there is no new conrods what are U supposed to do?

Apart from that she is bullet proof and your mates with Katana 250's wont believe it when you blow them away!

Oh and, if ya paint it black watch out for the cops. They are still looking for ours...235708

[Chalmes]

Yep, thats the one, the $1.1k from TM :)

Thanks for your replies....I wanted to remove the airbox so i could properly clean it out....the old filter has managed to get itself everywhere in there. Look's like i'll have to clean it in place. It looks to me that fuel has gotten in there and the foams perished.

Got the exhaust off no worries, just needed to move it back and forward a bit and it all popped out.

It won't get painted black.....am yet to decide on a colour scheme, but hopefully it will be quite striking.

I'm still toying with the idea of stripping it right down and repainting/cleanig form the frame up......but maybe not quite yet.

Time to get back into it, thanks heaps for the answers.

Jon