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Project My 96 Suzuki Across

Discussion in 'Your 250cc Projects' started by murdman87, Jan 6, 2016.

  1. murdman87

    murdman87 Well-Known Member

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    so i finally put the bike in the stand over the weekend and did some work.
    [​IMG]

    I decided it was time to replace the sad old engine as well as do some normal maintenance stuff: a new chain and sprockets, new rear disc and pads.

    the engine swap was fairly simple. with the help of my brother and a trolley jack we had it done in a few hours. this will be a very simplified guide on how i did it.

    take off all the fairings. drain the engine oil and coolant. disconnect the battery.
    [​IMG]


    [​IMG]
    remove the air box and carbs. i find it easier to leave the airbox attached to the carb and just pullit out in one. the manual says to disconnect the throttle cable. i did not do this for ease of reinstallation. pull the spark plug leads and mark them in some way so that you know what goes where.

    [​IMG]
    [​IMG]
    disconnect the shiter arm and undo the bolts holding the sprocket cover. i chose not to disconnect the clutch cable, and simply cable tied the cover up out of my way.

    [​IMG]
    i chose to disconnect cables on the engine side where able as it simply seemed easier. be sure to mark the cables in a way that makes sense to you. in addition to the three wires disconnected from the engine, there are a few that need to be disconnected from the loom on the brake side of the frame. these are easily identified and were simple to re route to the plugs later on.
    [​IMG]

    [​IMG]
    remove the radiator hose. undoing the bolts seemed the easiest way.

    [​IMG]
    dirty isnt it? remove the front sprocket and allow the chain to hang somewhere out of the way.

    [​IMG]
    remove the lower radiator mount, followed by the exhaust system, them remove the engine sub frame. i did have to nudge the frame gently to get it off.

    [​IMG]

    [​IMG]
    use a trolley jack to supprt the weight while you undo the engine bolts. i strongly recommend you have a friend handy to help guide the engine down.

    [​IMG]
    the new sprocket on the replacement engine


    at this point i cut the chain and removed the wheel
    [​IMG]

    [​IMG]
    [​IMG]
    replace the rear sprocket, rear disc and rear brake pads.


    from here you simply re install everything you have taken off, piece by piece until it starts to look like a bike again:
    [​IMG]


    i know there are a few things i should have got pictures of but this will have to do you.
    here is a quick vid to show that the new engine runs. bear in mind the airbox and exhaust are not on for this, and the carbs are not tuned. it was simply to prove that it fired.
    DONT FORGET TO FILL YOUR OIL AND COOLANT BEFORE FIRING YOUR ENGINE!



    cheers for reading :)

     
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  2. murdman87

    murdman87 Well-Known Member

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    [​IMG]
    forgot to mention i installed some LED rear indicators. also installed some load resistors to keep them legal. i rather like the look these give the bike.

    [​IMG]


    The tail lamp cover is currently smashed and held together with tape :(
    It will also be replaced by an LED lamp at some point in the future.
     
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  3. murdman87

    murdman87 Well-Known Member

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    just flushed and bled the brakes. i used green fluid as i find its much easier to see when it needs changing as opposed to the red stuff, which looks dirty from brand new.

    i will also be taking the carbs back out and giving them a good going over this weekend, not happy with the performance im getting atm.

    more updates to follow.
     
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  4. kiffsta

    kiffsta Senior Member

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    Coming along nicely mate
     
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  5. murdman87

    murdman87 Well-Known Member

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    thanks mate.
    part of me regrets putting so much effort into this bike rather than buying something better. but im a tinkerer by nature and i do get some satisfaction when things work out.

    i have also ordered a new windscreen that will hopefully arrive early january. there may also be a paint job on the cards. im thinking white with gunmetal graphics. i have to work out how to plastic weld before then to fix the crack on the side (you can just see it in the picks, near where the fuel pump is)

    all in all its a fun project, but i can see myself getting a newer bike in the future. one that hopefully hasnt had such a hard life.
     
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  6. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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  7. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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  8. murdman87

    murdman87 Well-Known Member

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  9. murdman87

    murdman87 Well-Known Member

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    I've added a new windscreen, and put in an led headlight globe over the last week. Pics of the headlight beam pattern to come. 20170126_145215.jpg
     
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  10. murdman87

    murdman87 Well-Known Member

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    Hey guys been a while.

    Bike was still running fairly crap the last few months. Finally got the time to look at it today and here's what I found.
    Replaced with a spare I had sitting around and went off for a ride.
    The difference is incredible. The bike is now running the best it ever has and I'm glad I didn't sell it a few months ago.

    20170723_143029.jpg
     
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  11. kiffsta

    kiffsta Senior Member

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    The old ripped diaphram on the across trick ... good score having spares on hand
     
  12. murdman87

    murdman87 Well-Known Member

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    I had purchased a spare set of carbies sight unseen off Gumtree ages ago. They are junk. All siezed up. But the diaphragm in one side was still good so it has saved me this time.
    I still have a lot to do on this bike. But slowly it is getting there.

    I need to:
    Bleed rear brake again
    Get new mirrors (current ones are junk)
    Check cam chain tensioner
    Check valve clearances
    Fix the choke
    Fix the rich idle
     
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  13. SukiMan

    SukiMan Member

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    Anymore work done to this mate? I enjoyed this thread haha


    Sent from my iPhone using Tapatalk
     
  14. murdman87

    murdman87 Well-Known Member

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    Nah mate nothing new. Work life has been hectic last few months haven't had much time to play with it.
     
  15. murdman87

    murdman87 Well-Known Member

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    Really need to get back into the bike!

    not a lot new to report.
    have rebuilt the front brake.
    drilled the exhaust holes out slightly. makes a lovely noise for a small bike.
    carbs still need work. rich on idle lean up top.

    but the bike is still running and regod and i take it to work occasionally. due for tyres though!
     
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  16. murdman87

    murdman87 Well-Known Member

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    My brother just noticed something interesting while we were doing a little maintenance.
    The new engine has a different oil capacity to the one I replaced. They are 100ml different.
    Was there a change in years or is one a gsx250r engine vs gsx250f?
    Anyone have any insight?
     
  17. murdman87

    murdman87 Well-Known Member

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    20190217_181240.jpg 20190218_142751.jpg
     
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  18. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Is that a 150/70-17 or a 140/70-17 rear Sport Demon ?
     
  19. murdman87

    murdman87 Well-Known Member

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    140.

    20190221_120000.jpg
    New rubber and a wash for rego check.

    Tried to give the carbies some love too but couldn't get it idling any better.
     
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  20. murdman87

    murdman87 Well-Known Member

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    Now have leaking fork seal to deal with too. Anyone have tips for someone who's never done forks before?
     

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