Project Bens GSX250 Cafe Project

No more airbox and carbs seals are all good. Figured it only runs with the choke out, and is getting hot quickly so its probably running too lean. Adjusted the screws all the way out and still it was only running with the choke out, but better. I'll get some bigger pilot screws so I can let some more air through

 

You mean go from a:
17.5 up to a 22.5
17.5 up to or a 27.5?

 

Just spoke to the crowd at Mikunioz.com in QLD and he says that because of the restrictive nature of the factory settings that jumping to a 22.5 pilot straight away should start the bike easier. They are $6.60 ea and postage is $8.

I'll let you all know how it goes when they arrive, in the meantime I'll try and fix these oil leaks from the cam cover and wait for my new tail light (I accidentally shorted the one I had trying to fit it)

 

Check out the key block my engineering mate made me. He laser cut it from stainless steel to the exact dimensions of the space and the orientation of the key.

Also I picked up a ninja guard for the chain just to pass roadworthy, cut it in have down the width and painted it matte

 

So the 22.5 pilot jets worked a lot better, the bike (at 2 +1/2 turns out) runs reasonably well and I dont have to use the choke. It still rushes a little on idle, perhaps I should go out a few more turns? Or go up another size?

I went up a size of main jets as well but she dies at around 4k revs. I think i'll put them back to regulars, they seemed to rev nicely.

 

So, that oil leak from the left cylinder, through the spark plug, most likely means my PCV valve is blocked that pumps the oil to the cams at the top. Okay, no real biggy right... I'll open the engine back up in a couple of weeks and put in new rings, and re-seal the engine with new gaskets after i've cleared the valve.

However, after playing with the new 22.5 pilot jets, and the biek starting better, now when I open the throttle it completely dies. And now the starter motor wont turn over due to pressure, its possible the cylinder is full of oil and it can't pump the piston anymore..... I am too new to all of this to get the bike running smoothly. I think i've screwed it up.

 

Okay so its not ruined, jumped it from the car and it went okay. But this is whats its doing throttle wise.

 

Thanks for the tip, I'll reset the pilot screws and try at 1/4 turn increments and see what happens. Its interesting that it would happily rev and hang on the old pilot screws, but it on the new pilot screws it wont let me open up. I wouldve though that would be main jets, but they havent changed...

You mean right before it dies? When i pull the choke out it starts to rev up again, past what it does if I just use the throttle.... does that answer your question??

 

Okay, so the spark plugs aren't wetting up anymore, so I'd say you're right its too much air.

The exhaust has a baffle, and I put the pods on (and tried with my hand over the carbs as well) but it still seems to want more fuel to run on idle, but dies when I twist the throttle.... its delicate balance is all out of whack

I started pilot screws all the way in and did quarter turns until it sounded like it was going to start. Still, the bike wouldn't run unless I pulled the choke in, but only a little bit this time. Still, no matter what now that I've gone up 2 sizes in pilot jets the bike wont rev when I open the throttle, only when I pull the choke in will it climb above three thousand revs.

1. Could the exhaust gaskets be the cause of an air leak? They are cheap chinese gaskets
2. Could the cam cover gasket be the cause of an air leak (because I know its not a perfect seal)?
3. Should I just buy some racing type carbs that dont care about restrictions and move on from these factory ones?

 

Firstly thank you for the guides. That should be helpful. I'll plug away at it with direction from MikuniOz and Show N Go's assistance.

Secondly, I know that there are very few mechanics willing to touch the bike, which is partly why I joined the forum. Bouncing ideas off people is really what i'm trying to do, I understand the complete answer is up to me, i understand people here might not be qualified, but talking out a problem and documenting both successes and failures helps me get the problem right and hopefully anyone else trying to do the same to the bike. I appreciate everyones assistance, likes and comments none the less.

And lastly I appreciate your honesty, however you have upset me. If you are talking on behalf of the community then I apologise for creating a frustrating experience. Please know it is only through my enjoyment of others projects that I undertook this hard task, and its been a great adventure.

~Ben