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GSX250F Junker fix up


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Page 4 of 5 First < 2 3 4 5 > Thread Tools 22-01-2011, 12:37 PM Display Modes #46

Glen
Rider

Stardate 22 jan 2011... or something like that. Rego is done! very painless overall, (except for the $202 fee) for an unregistered out of state vehicle. Mounted up my new plates and rego tube andddd First proper ride is out of the way with! Did 26km around the

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Join Date: Oct 2010 Posts: 433 Location: NSW Rep Power: 63

backstreets then got bored of that Sydney City Motorcycles and decided to head out a little Honda, Kawasaki, Suzuki and Yamaha Sales, further. Absolutely loving it so far. service and accessories www.sydneycitymotorcycles.com.au Only adjustment to the bike was the shift lever that was still to high up. i had to move it one spline over and tinker with the pushrod till it was right. My worries about the bike being too big turned out to be moot as well. feels very light once your moving. Didnt stall it once using the ride the rear brake method they teach at the pre learners course and felt way more comfortable doing it that way instead of just taking off with clutch and throttle (stalled it twice doing it that way >.>). Practiced travelling at real speed by waiting for cars to come across an empty intersection near my place then took off after em, working on keeping the 3 second gap and such. Helped alot with taking off from a stand still smoothly and quickly and being alot more confident in that overall. I think after another day of doing this ill be plenty confident enough to voyage out into some mild traffic Still a bit of a n00b with the blinkers and leaving them on tho so friggin hard reaching them on the across with my tiny little gloved hands haaha. Thatll come with time im sure. Last thing i did was conciously try countersteering. Very easy and i think ive picked it up pretty good. have to find a carpark to practice swerves and emergency braking now. She Definitely picks up a bit of speed after 11k rpm. Thought something was wrong the first time it lurched forward once it got up there hahaa. Most enjoyable Totally making the most of it before i get bored with the power LOL! Only things that didnt go to plan was when i was running through the gears for a bit of a laugh at a pretty slow speed, like 60kmh, i put it into 6th it made a pretty noticable clunking sound and lurched a bit. I think either a) i was going way too slow for 6th and b) did a half assed shift without the clutch in all the way. I reckon both are probably likely Also seemed to start surging so i went home. when i got off i could hear the fuel pump clicking like there was no fuel in it... I accidentally pinched the fuel hose in between the fairing and a frame rail before, but it didnt seem to be this time. i rerouted it yet again anyway and ill have another go tommorow. I have an inkling perhaps the fuel tap is stuffed. its VERY hard to turn of a morning when the bike is dead cold, and its corroded as heck on the outside. So when ive ran the thing out of fuel ill pull it out for a look Sooo tommorow ill just keep doing the same things as today and rack up some more K's. Then some slow trips out onto the main road through the week when its quiet. Practicing glancing around at everything quickly instead of putting so much focus into certain things, like side streets, is something i need to work on too. oh and my hands and wrists arent tired at all, so it seems ive lost my death grip

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'91 Suzuki Across

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tendancies

yey. No more buses for me

Ill stop boring y'all now. Im just excited as hell

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23-01-2011, 09:08 PM

#47

m.o.d.aus
Pillion Join Date: Jan 2011 Posts: 9 Location: QLD Rep Power: 2

Sounds like your having the time of your life man!! So jealious! Lol - still waiting for my bike... Must be so rewarding having rebuilt it yourself - huge props!

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25-01-2011, 01:12 PM

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#48

Glen
Rider

^^ Cheers, and yeah definitely is satisfying if annoying at times when more things to fix keep popping up What model are you getting? Did a pretty big trip, comparatively for me anyway, of about 60km around the area. In the morning the clutch was slipping like crazy and making it almost impossible to get going from a stop. Adjusted the clutch pushrod and its seemed to have stopped so far. I think im gunna be up for new springs and plates sooner rather than later though. ugh. Bottom end pull from 2000-5000rpm is pretty good, then it completely falls on its ass and barely accellerates through to 10000rpm without full power where it takes off again. Seems like this is a classic symptom of the clips holding the jet needles in failing, so im out to get some of them on thursday after big day out (anyone else going? ) Starting is much easier now, so i guess the old italian tune ups done wonders for that lol. only need to have the choke on for about 1 minute before riding off. Riding wise its all going quite well. Not too game to head onto the main roads without the mid range being fixed but some minor somewhat busy roads ive been out on and alls been fine. The only "oh shit" moment so far has been coming up on a bus that was sitting on the side of the road letting people off. I saw it quite early and set up on the brakes but didnt really slow down for it cause it was sitting there for aaagges, then it indicated to move out just as i was going past. Really should have slowed down much earlier and waited for it to go Bit pissed at myself for that one. But live and learn. Gunna set up my flipcam too and start getting some footage So yeah coming up soon, changing an across clutch and throttle clips

Join Date: Oct 2010 Posts: 433 Location: NSW Rep Power: 63

'91 Suzuki Across

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09-02-2011, 01:49 PM

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#49

Glen
Rider

Sooo two weeks later and im not dead and the bike is in one piece Spent the first week chasing problems with the carb and a wierd surging/stumbling issue at low rpm when the bike heated up. Which after a bit of research on the intertrons turned out to be a mixture of the idle being too lean and the midrange needles being too rich. Changing the throttle slid holders also helped a tiny bit. IMO i think the bike was previously tuned to run with an aftermarket pipe and a stock exhaust has been put back on it at some stage.

http://www.aussiestreetbikes.com/forum/showthread.php?t=11922&page=4

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Going one clip leaner on the needle and half a turn richer on the idle has sorted it out just nicely, but gawd what an ass of a job tracking it downs been. Seems the idle mix screw affects carburation at a far lower level then id originally thought. But none the less its sorted and runs very well all the way up to $1.80 Since then ive racked up 550km tackling every kind of obstacle i can find. Traffic lights, crappy roads, heavy traffic side streets, roundabouts (hate them so much! lol) and to be honest havent had much trouble aside from being a bit heavy handed with the throttle. I cant count how many times i thought i was doing 80 only to glance down and see 95 on the speedo >.> whups. really have to pay more attention there. Still need to get down to the new housing estate around here and practice with roundabouts. Im still a bit akward there especially the big two lane ones. Then get onto U turns. So yeah now im confident ill start doing a few more things to the bike First up is tracking down a set of rearsets to replace the shattered ones that are on it atm. Or more likely ill hassle my friends to knock me up a set on their CNC. Brakes are going to need to be looked at next service. The fronts are spongey and lacking in power plus i think they drag a teensy tiny bit. So a good clean and fluid change is needed thar i think. the rear disk is grooved badly. Im gunna jig that up on my lathe and turn it down myself when i have the rear wheel off next though. Also have to paint the fairings cause looking at the peeling wallpaper effect paint every morning is so brutally offensive to my eye haha. Not sure what scheme or colour to go with yet.. Something other than black. Sick of leaving it for 5 minutes and it being encrusted with dirt and stuff. Also not red or aqua blue as ive seen heaps of those around..

Join Date: Oct 2010 Posts: 433 Location: NSW Rep Power: 63

'91 Suzuki Across

Anyway thats my thought dump for the last little while! p.s. VERY dissappoint my helmet doesnt fit in the boot. WHAT USE IS THIS BIKE NOW D:!

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28-04-2011, 12:28 PM

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#50

Glen
Rider

Howdy again, Got a question for y'all but a bit of bling first. Cheap knockoff levers for a cheap ratty bike - Pretty pleased with em for $60 shipped. Theres no tension on the MC plunger at rest and the bore altho a little loose isnt too tight or anything. Ill machine up some bronze bushes to go in there anyway

Join Date: Oct 2010 Posts: 433 Location: NSW Rep Power: 63

So nice to have levers that dont have as much freeplay vertically as they do horizontally! :S

'91 Suzuki Across

http://www.aussiestreetbikes.com/forum/showthread.php?t=11922&page=4

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just an FYI for anyone the 2002 sv650 and 91 across (i presume all of em) use the same brake and clutch levers. And onto the question - Rebuilt the brake caliper with new seals and pistons, also did the master cylinder rebuild. Ive bled the brakes before in my minimotos (mountain bike hydraulics) easily but these.. omg. The fluid runs clear and ive cracked both banjos which are free of air but the lever travel is immense. Even bought a $100 vaccuum bleeder with no joy D: Tried bench bleeding the system and even had the caliper up above the MC.. Rotor has a little runout but within limits and it was working better before i rebuilt it. so i doubt thats it. Last thing was i bought a known working master cylinder in case i scratched the bore rebuilding the old one. No change. Lever travel is huge (almost to the bar) and it only gets solid when its basically touching the grip. Totally at my wits end with it now and just need someone else to look at it. x_x Anybody have recommendations for a good bike mech around mt druitt/penrith? PM me if you want. Would be ultra appreciated!

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28-04-2011, 05:45 PM

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#51

reddog
Rider

Maybe cable tie the lever over night and see how it feels in the morning. Other than that I'd say you have a big air bubble somewhere.

Join Date: Mar 2009 Posts: 2,222 Location: WA

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Rep Power: 91

'07 Suzuki GSF 1250S

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16-05-2011, 03:39 PM

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#52

Glen
Rider

Found some other little things to do while ive been bored. Exhaust flange on cylinder 3 stripped both its bolt holes out and blew off, fouling the plug and leaving the thing running on 3 cylinders about 100k from home. that was quite fun 8( Had to do some major surgery by drilling the holes 5mm deeper and retapping them, then winding some studs in with high temp permanent loctite. Its running better then ever now So ripping the front of the bike off was worth it i guess Also sorted the mysterious never heating up to temp issue. Its been shocking with this freak weather lately to the point it stalls at lights after a run on the highway. hrmmmm that shouldnt be >__>;

Join Date: Oct 2010 Posts: 433 Location: NSW Rep Power: 63

'91 Suzuki Across

Well thars your problem

Runs up to temp fine now. So i can finally ride in winter. Happy days

Now that the bikes all fine and dandy i wanna look into getting the headers and exhaust redone in the original black and look into upgrading the headlight and dash lights to something much more significant. And heres some nostalgia i found

http://www.aussiestreetbikes.com/forum/showthread.php?t=11922&page=4

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16-05-2011, 07:17 PM

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#53

Kritas
Pillion 1st Class Join Date: Oct 2009 Posts: 159 Location: NSW Rep Power: 42

Now THAT! is how you rebuild a bike! Great work Glen, wish I had the resources you do to get my project complete :jealous:

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20-08-2011, 02:41 PM

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#54

Glen
Rider

Well its been a fair old while, and since the last update I've basically been fighting with the brakes in a fairly mammoth struggle and i come with a question. See they were getting softer and softer to the point where it was getting fairly dangerous, so i figured a brake rebuild would be easy enough. Rebuilt the caliper totally with new pistons seals the lot, and slapped it back together with new fluid to find the brake travel was much much more massive than i remember (basically to the bar) and the month or so after that was just cooking up bleeding solutions.

Join Date: Oct 2010 Posts: 433 Location: NSW Rep Power: 63

Everything from standard style pump and open the bleeder type bleeding, to a mityvac to using a compressor on the M/C to god only knows what else i tried but it all resulted in huge lever travel with clear fluid out the bleeder.

'91 Suzuki Across

Ended up getting a new master cylinder and that made it a tad better but still the travel remained. Got sick of it and basically just dealt with the huge travel for a few months and only took a look at it today after i got my new HEL lines installed (they're for an 89 GS500 but they fit just perfect FYI!) and found the lever went a bit more solid but the travel remained (couldn't be swelling lines). This left only two parts i hadnt changed, the rotor and caliper body both of which worked before i ripped it apart.

http://www.aussiestreetbikes.com/forum/showthread.php?t=11922&page=4

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SOOOOO with that in mind and after some tinkering it seems the outer dust seals in the caliper are whats causing the huge amounts of travel. Seems they pull the piston back too far. I removed them both and the travel is great and lever dead solid. Now i think about it they weren't installed when i took it all apart either.

QUESTION BEING, what the hell do i do now!

i put over 4000km on the bike

before doing the brakes so they ran that long without dust seals but is it okay to run them without again? and if not what should i do about them sticking so badly? the internals of the caliper do look pretty shit, and i was thinking of getting a GS500 or SV caliper thats similar but with two big pistons instead of one small one large. Just need new pads to replace the fluid soaked ones and some new fluid (its been recycled through god only knows how many times lol) and hopefully ill be a happy rider again wooo.

http://www.aussiestreetbikes.com/forum/showthread.php?t=11922&page=4

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Cheers for any advice and help

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02-09-2011, 06:42 PM

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#55

Edwardos
Pillion Join Date: Sep 2011 Posts: 2 Location: SA Rep Power: 1

Hey man loving the work you've been doing it's been a good read. Just bought myself a 94 across and frickin love it. Plan to give it a minor overhaul not to the extent as yours though! Haha anyways I was wondering if you knew any guides for a chain + sprocket replacement and front and rear rotor and pads replacement?? I've worked on cars and stuff heaps before it's just I'm not experienced in bikes at all. If I have a decent guide I can usually tackle most things. Any help would be appreciated greatly Cheers

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02-09-2011, 07:00 PM

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#56

Glen
Rider

Hey welcome! Yeah you'll be fine, its all easy. I'm doing the pads early next week so ill take some snap shots. Only thing you'll need is an allen key bit for a torque wrench to do the front caliper bolts up. I might have enough pics here to do a sprocket guide, ill chuck it up soon if i find em! But its very straight foward too. You'll need circlip pliers and a chain rivetting tool The service manual is really comprehensive too, it'll outline everything http://www.dixonarchive.com/across/g...ice_manual.pdf

Join Date: Oct 2010 Posts: 433 Location: NSW Rep Power: 63

'91 Suzuki Across

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02-09-2011, 07:45 PM #57

Edwardos
Pillion Join Date: Sep 2011 Posts: 2 Location: SA Rep Power: 1

Awesome yeah I didn't think it would be overly complicated or hard but a guide just makes me feel better haha. I might miss a few tips/tricks without one. Cheers for the link also very helpful

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02-09-2011, 08:11 PM

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#58

extermin8tor
Rider

Originally Posted by Glen Hey welcome! Yeah you'll be fine, its all easy. I'm doing the pads early next week so ill take some snap shots. Only thing you'll need is an allen key bit for a torque wrench to do the front caliper bolts up. I might have enough pics here to do a sprocket guide, ill chuck it up soon if i find em! But its very straight foward too. You'll need circlip pliers and a chain rivetting tool The service manual is really comprehensive too, it'll outline everything

Join Date: May 2010 Posts: 1,548 Location: SA Rep Power: 443

'03 Suzuki GSX-R 600

http://www.dixonarchive.com/across/g...ice_manual.pdf

Bloody hell my GPX has the exact same brake problems. I've replaced the master cylinder to a brand new 2008 ninja model. Rebuilt the calipers, fitted braided lines and it still feels like shit.

http://www.aussiestreetbikes.com/forum/showthread.php?t=11922&page=4

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Do you reckon its okay to run the brakes without dust seals? It's not really gonna be raining for the next while, so dunno.... My rear caliper was missing a dust seal anyway until I rebuilt it. I tried cleaning the crud out of the dust seal lip on the caliper, but it still feels like crap when braking. Better than lever to bar like it was originally but still crap....

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02-09-2011, 08:22 PM

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#59

Glen
Rider

@extermin8tor Personally yeah its okay to run without the seals for a little bit, i have at least, then again this is all learning through experience lol. The bike didn't have them when i got it and i've put alot of Ks on it since then. But i'd rather they be there. By all logic the brakes SHOULD work with them in there and thats whats aggrevating! I did read in some obscure library book that the seals are tapered. Visually i cant tell and the across service manual made no mention of it, but i tried the dust seals both ways and it didn't help, so i think there's 3 things to try.

Join Date: Oct 2010 Posts: 433 Location: NSW Rep Power: 63

1) is try the main seals the other way round and see if they are tapered too 2) is grab some caliper assembly lube from supercheap, i saw some there for $12 the other day 3) do a better job scraping the seal bores. I reckon thats the main issue. Ill be making a much better scraper this time and really having at it till they are back to bare metal with no marks at all. Cause i guess if that's done it has to be a seal issue! Will let you know how i go on monday

'91 Suzuki Across

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03-09-2011, 12:11 AM

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#60

extermin8tor
Rider

Yeah sounds good I scraped the bores really carefully with a diamond pick and blade, got lots of crud out, its pretty square now. My dust seals weren't tapered and they were pretty symmetrical. Might just not bother messing around with it as I am selling the bike soon anyway!

Join Date: May 2010 Posts: 1,548 Location: SA Rep Power: 443

'03 Suzuki GSX-R 600

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