GSX-R 250 Project Update

[j_redley]

Just for anyone who actually gives a fuck, and even those who don't. I brought the bike not going with the engine having been in peices for valve re-surfacing. It was half assembled when I brought it, with one coil not hooked up, carbs not connected properly, and gear shift linkage and chain etc not on. Also has a small crack in the top fairing and rear brakes need repairing. For $450 I'm pretty happy.

Got stuck into it today and finished connecting throttle and choke cables, as well as the coil and checked the timing before seeing if the motor would crank. Used a jumper battery and pleasantly the motor turned over. Added oil and some petrol into the carb's and tried again receiving a few splutters. Check spark and only one coil was giving a spark. Narrowed problem down to no power supply to the other coil, then ran out of time in my lunch break. Target tommorow is to narrow down this wiring fault/loose connection and get the old girl running. One step at a time...

[j_redley]

Fail!

Hooked up the 2nd Coil, checked power and then asked the work experiance boy to reconnect the batterys I had disconnected whilst playing with the wiring. Didn't check what he had done, and hit the stater switch to hear an exceptionally fast spinning of the starter. Wondered what the hell had changed, glanced at the wiring and finally at the batterys to discover the dick had hooked the jumper lead up to the 2nd battery, thus 24volts through my bike. An easy mistake to make given we are a Truck Garage and usuall jump start at 24 v, but when I put them on 12v again and turned the bike over, I now have no spark at all.

A little investigation and it would appear the CDI is fucked, which is a wax sealed unit. Priced one at $140 from bike wreckers in Rotorua which is annoying as all hell, so will be cutting the wax to check for a blown diode next week...

[neels]

Fail!

Hooked up the 2nd Coil, checked power and then asked the work experiance boy to reconnect the batterys I had disconnected whilst playing with the wiring. Didn't check what he had done, and hit the stater switch to hear an exceptionally fast spinning of the starter. Wondered what the hell had changed, glanced at the wiring and finally at the batterys to discover the dick had hooked the jumper lead up to the 2nd battery, thus 24volts through my bike. An easy mistake to make given we are a Truck Garage and usuall jump start at 24 v, but when I put them on 12v again and turned the bike over, I now have no spark at all.

A little investigation and it would appear the CDI is fucked, which is a wax sealed unit. Priced one at $140 from bike wreckers in Rotorua which is annoying as all hell, so will be cutting the wax to check for a blown diode next week...

That sux

I can attest to the fact that these are great fun little bikes to ride, my son has one and I love riding it, I just hope it takes him a while to learn how much fun it is when you get it up near redline.

I'll PM you the email address of a guy that's wrecking a couple of these in chch that I was talking to about bits for the boy's bike, he may be able to help you.

[j_redley]

Cheers for that, got a new CDI coming in at the beginning of next week after payday. In the mean time, gonna be putting the gear shift linkage in during the week so that apart from the CDI, it should be alot closer to ridable once I get it.

Other than that, a new oil filter and the engine side should be nearly done, just gotta balance the carbs and see where to. I've got a plastic welder lined up to repair a small crack in the fairing, and from there I might even rub down the rest of the fairings this week too. Got some high gloss black 2-pot paint to shine her up. Gonna be impatient as hell this week waiting for the CDI, hopefully the rectifier isnt shot.

[j_redley]

Been a while and I've been busy with other things but finally got my CDI all plugged in. Hooked the battery up (12v this time) turned her over and didn't get a running sound. Checked, and I've again only got spark from one coil. Power's at the coil so its an earth fault. Had a quick look but I get pissed off quickly when it comes to tracking those down, so left that for now and sanded the entire tank down, including removing stickers. Bogged up all the tiny blemishes and primed today.

Started looking at the wiring and decided to just see if it would pop and fart on two cylinders. Used a syringe with petrol and some Start yah bastard to discover that timing is out and it fires it all back out the carb's. So, I'm back to removing the rocker cover and double checking and most likely changing the timing. Hopefully I get this done by summer cause I'm itching for a ride again.

[DarkLord]

Sounds like an awesome little project that you are learning a lot from. Good on you for getting in there and giving it a go. Big ups to you.

[j_redley]

Cheers! Finally got well and truly stuck in, got a new Pick up and found out the spark plug wiring was wrong, fired it up and strummed into life just sounded a bit off when revved up. So, took the carbi's apart cleaned the jets and adjusted float heights, installed the air cleaner and she runs like a gem, starts first time and no smoke!

Installed radiator and stuff last week, checked for leaks and no evidence of coolant in oil, so seems good there too. Sanded down and primed tank, sanded and gave a second layer of primer today. Gonna do a bit of bogging either over the weekend or monday, then a few more layers of primer before I put on the 2-pot hard black paint.

Oh, and I put some grips I got given on too. Just gotta get the fairings cleaned up next, one ignition barrel and away we go!

[Gibbo89]

Just had a read of your posts, how are things going now?