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Help gsx400 flywheel on gsxr250r gj73a and other problems Now Running with Video :)

Discussion in 'Suzuki 250cc In-line 4's' started by CobraBaz, Jan 27, 2021.

  1. thebeefsalad

    thebeefsalad Well-Known Member

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    Oh man, first time with a 4 stroke and an i4 and managed to get it done?! Gives me a lot more faith! I've rebuilt 4 strokes, but only single cylinder motors. Glad those rebuilds got a lot of the learning curve out of the way, but the CBR is it's own beast with it's own nuances I'm certain. I can't wait to hear you rip this thing down the street! (on video of course...)
     
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  2. CobraBaz

    CobraBaz Well-Known Member

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    Its not far off m8 ,,, i keep ploddin along :)
    Its not been to bad with the bike beeing very good condition apart from rotor problem,,, but it`s deffo give me confidence to try and repair more, i didnt intend doing all what i done , i thought i could just replace flywheel stator and casing,,,,, but soon was obvious it wasnt gona be that straight forward :(,,,,but after gettin the bike home and watchin videos ect about em ,, i jus had to try get it sorted and many thanks to Simon for lots of help an advice its allmost ready for that video m8 :)

    ps ive only re-built a cbr125 top end about 6 month ago before this :)
     
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  3. CobraBaz

    CobraBaz Well-Known Member

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    Electrolysis complete ,,, swilled tank in shower and runs all clear :)
    Few pics of inside tank with my little £6 borescope,, didnt get before pics as camera had not arrived but it was quite rusty when i inspected propper,:)
    First time trying electrolysis but i will be doing more,,, used for plating ect from what i learned !!! StillSnapshot000003.jpg StillSnapshot000011.jpg StillSnapshot000013.jpg StillSnapshot000024.jpg StillSnapshot000021.jpg StillSnapshot000009.jpg StillSnapshot000012.jpg StillSnapshot000019.jpg
    Looks rather freckely on the inside but no loose crap and water runs clear after rinse ... so plugged the fuel cock hole put lid back on and emptied a can of wd-40 inside and swilled about,,,,,,
    gone do another swill with fuel tomorow and hopefully get it runnin off its own tank :)
    Another step closer to atest run,,,,, cant wit :)
     
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  4. CobraBaz

    CobraBaz Well-Known Member

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    Found the hole ;)
     

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  5. CobraBaz

    CobraBaz Well-Known Member

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    IMG_20210301_133018.jpg IMG_20210301_133640.jpg
    Not perfect but should be OK until I source I good tank and respray,,,, have to try get graphics remade to,,
     
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  6. CobraBaz

    CobraBaz Well-Known Member

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    All back together and no petrol leaks as yet,,,,,,, just been for First little go up the front,,, first time its gone under its own steam in about 11 year , Yeee Haaa,,,, the sound deffo turns heads my neighbours musta thought i was doin 120 the way they looked at me haha
    When it goes it goes and sounds sweet as but its a bit boggy under 4000rpm setting off and stalls sometimes ,,, think the carbs in need of a tune and balance, and i`ll order a new seal kit for it soon as i can, but catch it above 4000rpm and it rips!!!!
    Also got a little oil leak from stator gasket but i got a new one here :)
    Apart from indicators not working and gota find rear light for it everythin else seems to be well
    Was a proud moment riding up the road a few times i must say,,, cant wait untill its perfect!!!!!
    I`ll get a lil Video next time :)
     
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  7. CobraBaz

    CobraBaz Well-Known Member

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    Been havin a read and a youtube about mixture settings ,, lean/rich ect,,,
    anyway after removing carbs and finding where they are i wound them all in and wound out 2 3/4 turns ,,, it seems to of helped the revs hanging a little so gona try richen up a lil more tomoz and see how that goes and take for another lil run and check plugs :)
     
  8. CobraBaz

    CobraBaz Well-Known Member

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    Just secured myself a better condition tank, off Moff an old member from here ,,, excellent condition inside and out but has a small hole underneath and a small dent but will be re-sprayed anyway gona look in to gettin it repaired the best way possible but theres no rush,, got a bargain :p
    Also will need to get tank graphics re made!!!!
    the tank is all that lets this bike down really so its gota be fixed :)
     

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  9. CobraBaz

    CobraBaz Well-Known Member

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    tuned the carbs a little & revs dont hang as much,,, but seem to have a fueling problem,, bike runs great about 300 yard givin some squirt,, then seems to run out of fuel,,, hit the starter a min or so then it fires and same again,,,,
    any ideas??
     
  10. CobraBaz

    CobraBaz Well-Known Member

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    Got a little video after tuning carbs a little,,, its better revs dont hang as much,,, gona tweek a lil more,,,,
    But seem to have a fueling problem,,, its like it runs out about 300 yard up the road,,,, turn it over a few times ,, goes again ,, then same happens,,, any ideas??
    Apart from that it seems to be pretty good :)

    video made me with my video glasses lol
     
  11. thebeefsalad

    thebeefsalad Well-Known Member

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    Is the petcock vacuum operated? Are the carb slides possibly hanging? Sort out the idle tune, that's not helping it stay running either.
     
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  12. CobraBaz

    CobraBaz Well-Known Member

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    yeh vac operated petcock,, it idles ok m8,, it will start & tick over fine ,, jus when run up the road after beeing under load it dies, then it takes a lil while to start like its pullin fuel through again,,, havent really got much space to test but ive only ever got up the road and back at the most without re starting,, have been pretty quick to :) ,,,,, , not sure about carb slides gona have a think about it and maybe strip petcock then carbs tomorrow,,,
    its all a learning process m8 and its almost there :p
     
    Last edited: Mar 4, 2021
  13. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    Just seen it..looked everywhere on the inbox one and then thought to look here! go easy on that starter..or changing the brushes u'll be next! Not a bad effort for a first engine rebuild I might add m8 now its moving under its own steam :)

    Fuel screws are at 2 3/4 turns???? Standard is 1-1.5. Bike will be horribly rich and revs will drop below idle everytime m8. Start with a stable idle..it may do this all day on the sidestand but here is an easy way to check:

    Start by taking all the fuel screws out - check the rubber seal. If there slightly perished/cracked/swollen or otherwise replace. Otherwise idle mixture will be inconsistent. You'll end up chasing your tail. You can use any o ring that fits until you get your seals delivered from Litetek - just be aware that its not a fix for long unless there made of the propper material. Not sure if you know how to tune the idle mix by ear but i can show you a way using a tach (multimeter), or the easiest way that will get you close is as follows:

    Turn the screws all in (after sorting the seals above), then out 1 turn. If the revs dont drop to idle quickly..(it hangs),turn them out 1/8 of a turn. Recheck. Continue going out an 1/8th turn each time until the revs don't hang or the bike momentarily goes slightly below idle and then recovers back upto normal idle speed. Note this position. Do the same again after turning the screws in 1/8 turn..this time with the engine under a bit of load (put the headlights on full beam). If the revs don't drop below idle your there or there abouts. Test ride. If good, continue with next issue. If not fixed..take the tank/petcock out of the equation and recheck with a dummy tank (your self made one work of art will do!). Test ride. If good continue with next issue and fix the tank vent/fuel cap vent/petcock issue. If not fixed..check fuel levels in the bowls. If fuel present then suspect worn emulsion tubes/needles.

    I'd deffo do it AFTER all the seals are done with the Litetek kit mate..good luck pal let us know if your unsure will do my best to help!
     
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  14. CobraBaz

    CobraBaz Well-Known Member

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    Yeh gona get out my tools and start some investigation soon,,,, im not to concerned,,, its only a teething problem as when it goes its sound m8,,,,
    Im enjoying learning more about my bike to :p
     
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  15. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    :):):):):):):):) they'll be a day soon when the sun shines, the bikes on full song, lockdown will be ended..can't come soon enough!
     
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  16. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    With the tank... try a radiator repair place. if it is only a pi hole they can braze it up or Silver Solder it etc...
     
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  17. CobraBaz

    CobraBaz Well-Known Member

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    Just stripped and re-built carbs and put to stock settings,,,,,,
     
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  18. CobraBaz

    CobraBaz Well-Known Member

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    Got fresh Carb kit seals, emulsion tubes needles ect
    Keyster Kits jus got here, so stripped em again and found another problem,,,, the Brass tubes for choke system, one has snapped right off and another has split and one has been replaced,,,,,
    After a root about these don’t look to be available, so gona order some brass model tube and re-make some of them , shouldn’t be to hard lookin at the one that has already been done :)


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  19. CobraBaz

    CobraBaz Well-Known Member

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  20. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    You probably already know this, but those are Keyster tuning kits not carb kits.
     

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