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Project '98 Suzuki Across

Discussion in 'Your 250cc Projects' started by Laceysnr, Aug 8, 2019.

  1. Laceysnr

    Laceysnr Member Premium Member

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    Seems to have been used by a few people to good effect: http://www.mightyram50.net/vbulletin/showthread.php/2642-How-to-Soften-Old-Hard-Rubber

    I'm also thinking it's unlikely to be the cause right now, but given how clean I believe the carbys are I'm really running out of ideas. New plugs could be gapped wrong but not sure that'd require a tonne of extra fuel from the carbys?

    Once I got them apart last night I spent a decent amount of time trying to get my bench sync as close as I possibly could, with some luck that'll help. Guess we'll find out tonight depending on how fast I can get it all back together. Don't really want to be firing it up much past 9pm because they're sure not quiet 250s :) I'm pretty sure my wife will be happy for me to buy a heat gun if it stops me stealing her hair dryer.
     
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  2. Laceysnr

    Laceysnr Member Premium Member

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    Didn't get around to rebuilding the carbys until yesterday, but took my time and blew compressed air through anything and everything. Then I checked the float heights and found them to be at the high end of the acceptable range (i.e. lowest fuel level) and tweaked them to the other end of it for good measure. Had to use a kiddy's ruler to do the job but it seemed ok :D

    Connected everything back up, wound some silicone tape around the boots on the airbox (left the carby boots as is) because some of the rubber welding stuff was decomposiing and had a few holes, and then turned the ingition. Fuel promptly pissed out of the breather onto the floor making me think the floats were set too low, but once it had filled the bowls it stopped, and hasn't done it since, so I think it was just splashing around a bit on the initial fill. Crossed my fingers, burned a new spot on a my screwdriver shorting the solenoid and she almost started. Tried it again with a little throttle and she sprung to life!

    Needs tuning still, but it's starting fine now with the stock mix (1 1/2 turns out) on the screws, and will let me back off the choke once warm. Pretty damned happy with that!

    https://photos.app.goo.gl/A294uV1hnhXPr93H9

    Next up: cleaning and refitting the brakes, fixing the starter switch wiring and then putting it all back together. Hopefully on the road just in time for spring.
     
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  3. Andych

    Andych Well-Known Member Premium Member

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    Well done... could well have been the airbox boots that were throwing it all out..
     
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  4. Laceysnr

    Laceysnr Member Premium Member

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    Well the starter switch works, and it wasn't a broken wire as I thought. Can somebody tell me where on this diagram there's a switch on the goddamned clutch?! (Edit: I mentioned two diagrams before, neither has it, but I don't want to share too much of the manual since it's easily worth the $10 premium membership).

    upload_2019-8-26_22-42-2.png

    Guess it must have been a later revision? So the lack of continuity was just a lack of me pulling the clutch in. Oh well, brakes, reassembly and tuning to go.
     
    Last edited: Aug 26, 2019
  5. Laceysnr

    Laceysnr Member Premium Member

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    Disassembled, cleaned, refitted and refilled the rear brake, got the front one still to do. She was still running quite rich so whipped off the carbys again and set the floats to mid-range (as best as I could). Managed to get them off, adjusted, and fully installed in under an hour, clearly getting too much practice with them.

    Still smokey when on the throttle, but warm idle is pretty decent. Still plenty of **** being fired out of the exhaust when she revs up too so I think it's going to take a while to clean out. New tyres are coming Monday and then once the front brake is done I'll book her in for a roady. Fingers crossed!
     
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  6. Jethalter

    Jethalter Active Member Premium Member

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    Could simply be for the most part the bike just needs a good run also.
     
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  7. Jethalter

    Jethalter Active Member Premium Member

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    how have you progressed with this so far ??
     
  8. Laceysnr

    Laceysnr Member Premium Member

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    Not too bad, she had new boots put on last Monday. I was looking at the old ones and noticed some pretty bad cracks, and even though I found a number that was something like "2613" the guy who replaced them didn't think it was actually a year code and actually thought the tyres had been on there since new. The state of the rims inside the tyre backed that theory up, as well as the fact that it had original Suzuki branded weights on the rim!

    Apart from that I cleaned, reassembled and re-fitted the rear caliper, and then set about the front. No grease gun but I used the air compressor and got one of the stuck pistons to pop out, so wedged that and tried to get the other loose... that thing was seriously stuck. Took a good 60+ PSI in the end (needless to say I had googles on and had it pointing straight down at the bench top) and it finally came out. Cleaned up the pistons and the housing and put it back on. Then struggled to do up the bango bolt... pulled it out to check I had it lined up right, and heard plunk as one of the crush washers fell off and down into the bike. Swore a lot, hunted high and low, but couldn't find it. Ordered some new ones Friday, and then yesterday the bugger finally fell out of the bike after riding it up the driveway and into the garage. Nearly stacked it into the beer fridge forgetting that I didn't have a front brake!

    Anyway, going to refill and bleed the front brake tonight, and then I think she's good to go for a road worthy. Still struggling with the mixture tuning a bit, and need to rig up something to balance the carbies but I'll get there. Looks weird seeing her with all the farings on again! I've read about finding the mid point between the two places where the revs drop for the idle screws, but as I wind them out it never bogs down, just revs higher and higher. Might just get the place that does the roadie to take a gander for me.
     
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  9. Laceysnr

    Laceysnr Member Premium Member

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    Update because it's been a while! Refilled the front brake, paid for an unregistered vehicle permit and had a few rides up and down my road to test the brakes. Not exactly amazing, but then the back was stepping out so I think it's just a combination of me being unused to an older bike with softer forks than my CBR500 has, and the new tyres because they're not scrubbed in yet. Either way, took her for a roadie on Friday and she passed, so next up is Vic Roads on Thursday to get her registered again. I couldn't help but open it up on the way to the roady and discovered a flat spot around 11.5k, really didn't want to go past there and I know the jets are clear, so got some investigating to do, but that can wait until I can ride her around a bit more and actually give her a decent run.
     
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  10. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    give her a good run for a few hours then pull your plugs so she how she is going ?

    Congrats on getting it this far, you have done well.
     
  11. Laceysnr

    Laceysnr Member Premium Member

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    Thanks mate, in a bid to get the earliest Vic Roads appointment that I could I've actually got an hour and fifteen each way for that, so she'll get a good run then. Think I'll be putting plenty of tools in the boot before I set off!

    Sent from my TA-1052 using Tapatalk
     
  12. Laceysnr

    Laceysnr Member Premium Member

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    IMG_20190919_142452.jpg
    Rego'd and on the road :D Clocked up 200km today (which my back can attest to). Ran really well though still hesitating a bit over 11k. She will power through to the red line but definitely not quite right. Other than that I had a heap of fun though.

    Oh, also got to sort out the bloody idle adjustment screw.... could never get it sat back right after re-installing the carbies and can't back it off atm, so once she's warm she's sitting at 3,500! On the bright side, I got to test the boot with a nice cold 6-pack.
     
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  13. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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  14. Laceysnr

    Laceysnr Member Premium Member

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    During all my tests at home she was idling nicely at 1700, it's only after 20 minutes of riding that they were high, but I'll have a tinker and see what happens. I found if I kept winding them out she never bogged down, the engine would just keep on revving higher and higher so there was no way to find a mid point. I just wound in until I heard it slow and then turned back 1/2 a turn, so it's definitely approximate at best. Also need to get/build a manometer and sync the carbies. Did that by ear based on listening to where the revs would increase in each direction but would pay to get it more accurate I'm sure.
     
  15. Jethalter

    Jethalter Active Member Premium Member

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    I got a carbtune if you need to use it.

    Yeah the across is a pita with carbs, i still can't get mine 100%, but mine is just cold start fueling issues, when warm its sweet.
     
  16. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Definitely take up @Jethalter offer it will make a difference.
     
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  17. Laceysnr

    Laceysnr Member Premium Member

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    Might well do that! I'm overseas for a couple of weeks from Saturday but might have to ride her your way after that @Jethalter.

    Sent from my TA-1052 using Tapatalk
     
  18. Jethalter

    Jethalter Active Member Premium Member

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    yeah no rush, i got a few things to catch up on but should be good by then
     
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  19. Laceysnr

    Laceysnr Member Premium Member

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    So I borrowed a Carbtune today that was a little more local... I rode her to work and then to pick it up and she was feeling better than before, pulling better over 11k rpm which is nice. I hooked up the carbtune later in the evening, let it warm up to where it idles just under 2k (when it's hot it's idling at 4k, so from everyone I've talked to that seems to be a vaccum leak).

    It was pulling way harder on one side than the other, completely unbalanced. But if I wound the screw to adjust it before I got them anywhere close to even the revs would be climbing really high (as in 7k +) and it was obvious I was basically just opening up the throttle on that side at that point.

    I tried that using the ports on 1 & 4, and then 2 & 3, and got the same result: the carby on the right (3 & 4) is pulling harder. So now I could do with some advice as to what to look for - is this a good indication of a leak on the left hand side? I sprayed some Start Ya bastard around the carby boots on that side but without any effect. At this point am I going to have to start looking at tappets? As much as I've loved getting stuck into this bike I reckon that's the point where I'll have to take it to somebody else to look at.
     
  20. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    When you're syncing the carby's you may need to drop the idle speed back down to normal as it get's close to perfect balance
     

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