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Info Ade's 1988 Suzuki GSXR250RR

Discussion in 'Your 250cc Projects' started by monsigna, Dec 2, 2014.

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  1. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    Th3_Huntsman, Dec 19, 2014
    #81
  2. monsigna

    monsigna Active Member

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    im going to remove the engine, blast & paint the frame, and reassemble to the point where I can try and start it. tank/carbs/coils etc..and go from there, got to drill & tap the head for the two new exhaust bolts. Im quite optimistic that it will run, that's the only thing the seller assured me, that it was a very good runner, well tuned.
     
    monsigna, Dec 20, 2014
    #82
  3. Murdo

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

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    Had to get a broken off bolt out for a friend today, so thought I would take some pictures of how the left hand drills work. Note the different twist.
    001.JPG
    Bolt in Suzuki chain adjuster had been bent ( a common problem with this style adjuster), so cut off neatly with hacksaw.
    002.JPG
    Drilled a 2mm hole about 10mm deep.
    003.JPG
    Using the left hand 5mm drill was able to get it to 'grab' the broken bit and wind it out.
    004.JPG
    Sorted.
    005.JPG
     
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    Murdo, Dec 20, 2014
    #83
  4. Fox McScrooge

    Fox McScrooge Well-Known Member Premium Member Contributing Member

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    Has anyone had a chance to try those Grabit drill out tools? I have always used Easy Outs in the past but they look like they might be OK?
     
    Fox McScrooge, Dec 20, 2014
    #84
  5. monsigna

    monsigna Active Member

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    You have seen the state of my corrosion, where both materials have literally welded together, personally, I think the only way is to drill and tap, but I'm willing to try new things. I have a good quality set of easy outs on the way, and I may invest in some LH drill bits. Cheers for the tips.
     
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    monsigna, Dec 20, 2014
    #85
  6. Murdo

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

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    One more tip then, if you break an ezy-out off the best way I have found to burn it out is with a plasma cutter.
    My mate bought a Honda CRF with a broken ezy-out in the adjuster bolt of the alloy swing arm, and careful use of the plasma got the bolt melted out without damaging the alloy.
     
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    Murdo, Dec 20, 2014
    #86
  7. Mclaren

    Mclaren Well-Known Member Contributing Member

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    Other option is a carbide drill to get snapped ezy out or drill
     
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    Mclaren, Dec 20, 2014
    #87
  8. monsigna

    monsigna Active Member

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    A bit more progress today....

    10857788_10203422043175155_6605475215220152996_n.jpg 10689530_10203422043415161_4126948473955680821_n.jpg 10386817_10203422043935174_7944903397084908620_n.jpg 1506820_10203422045855222_7545345417899271338_n.jpg 10858076_10203422046455237_3966529679845233485_n.jpg 10671308_10203422046935249_3546996185775566570_n.jpg 10461389_10203422170018326_5268407475197767921_n.jpg 10345839_10203422170978350_2559583827050173477_n.jpg 10382170_10203422171538364_6365383725169399867_n.jpg 10881847_10203422287381260_4001577629888330027_n.jpg 10846410_10203422726832246_950089748623859370_n.jpg 10882197_10203422859155554_6292904779487269250_n.jpg
     
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    monsigna, Dec 21, 2014
    #88
  9. monsigna

    monsigna Active Member

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    That took all day to get the finish I was looking for, but well worth it.
     
    monsigna, Dec 21, 2014
    #89
  10. soames

    soames Well-Known Member

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    Got a set of grab it bits today will let you know if there any good soon as I use them they just look like reverse ream CNC bits
    Nice clean discs there monsigna might have just tempted me to pull mine off and leave them for Santa to clean lol
     
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    soames, Dec 21, 2014
    #90
  11. Phil

    Phil Senior Member Contributing Member

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    Looks awesome, what a great job you are doing :thumb_ups:
     
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    Phil, Dec 21, 2014
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  12. Moo

    Moo Plodge Racing!!!

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    and he splashed out on easy outs!! good man!!
     
    Moo, Dec 21, 2014
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  13. Tim_

    Tim_ resident nutcase Contributing Member Dirty Wheel Club

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    makes me want to buy a parts washer :oops:
     
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    Tim_, Dec 21, 2014
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  14. Boydie77

    Boydie77 Well-Known Member

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    OK, I pulled the RGV shock out today and as suspected, it's dimensions are identical to the GJ73a :) Shock length eye-to-eye is 310mm.
    WP_001728.jpg
    Top shock is GJ73a, middle is RGV, bottom is the WP unit I'm putting in mine. This is requiring a bit of cutting and griding to fit in my 73. If there is room around the top of the shock for a piggyback reservoir an 03-06 CBR600RR shock is a straight bolt in.
     
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    Boydie77, Dec 22, 2014
    #94
  15. monsigna

    monsigna Active Member

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    Been at it again today, removing broken bolts from various bracketery. There no such things as 'easy outs' blummin rubbish! I started on the thermostat housing, as I could drill right through, giving me half a chance if the easy-out snapped.....and it did. As I had access to the rear of the hole, I fashioned a masonry nail and tapped the broken easy out tool from behind. Thank goodness i had the sense to drill right through.
     
    monsigna, Dec 23, 2014
    #95
  16. monsigna

    monsigna Active Member

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    10268415_10203433714266925_8758319475047327429_n.jpg 10885540_10203433714626934_2760771975644444706_n.jpg 10885289_10203434095916466_8024540381944656374_n.jpg 10868287_10203434241000093_645065000417287231_n.jpg 10857756_10203434244640184_5322768324353144161_n.jpg 1613890_10203434451445354_1043799031129734303_n.jpg 10881506_10203434462405628_9006356336742608219_n.jpg 10885011_10203434464045669_8786156403114123777_n.jpg What a croc...... 10426178_10203433713826914_6462294582714922900_n.jpg
     
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    monsigna, Dec 23, 2014
    #96
  17. monsigna

    monsigna Active Member

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    one hole was good (M6 1.0) the other hole's thread was erm....not good, so I tapped it out to M7.all is well....still not sure how the broken alloy around exhaust apertures is going to perform.....it will either be gas tight....or not. there's not a lot I can do about it with virtually zero budget. I have some chemical Metal, I have used it before, just not around areas where there are extremes of heat. Any advice chaps?
     
    monsigna, Dec 23, 2014
    #97
  18. Moo

    Moo Plodge Racing!!!

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    wow a broken easy-out............thats something i haven't seen before.....hummmm
     
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    Moo, Dec 23, 2014
    #98
  19. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Aaagh I hate those tapered easy-outs. They expand the bolt as you try to remove it. Completely stupid design.
    Use heat, Murdo's left hand drills and Ridgid screw extractors. A small propane torch will do wonders. Aluminium expands very quickly and the steel bolts will not.
    [​IMG]
     
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    Last edited: Dec 23, 2014
    maelstrom, Dec 23, 2014
    #99
  20. monsigna

    monsigna Active Member

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    Looks like my next investment maelstrom
     
    monsigna, Dec 23, 2014
    #100
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