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Project Bens GSX250 Cafe Project

Discussion in 'Your 250cc Projects' started by Ben Mulligan, Nov 14, 2013.

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  1. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    First thing to do is believe nothing from previous owners .
    Second thing to do is clean the connectors (and if its ok and usuable , clean the unit of grease and dirt as its finned for cooling)
    Thirdly , follow this testing procedure ..... :D

    GSX RR testing.jpg
    GSX RR testing 2.jpg
     
    GreyImport, Jan 15, 2014
    #81
  2. Ben Mulligan

    Ben Mulligan Well-Known Member Premium Member Contributing Member

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    I was hoping you wouldn't say that, means I have to rewire the bike before I can find out if its defective or not.
     
    Ben Mulligan, Jan 15, 2014
    #82
  3. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    No, its done with the unit disconnected

    disconnect.jpg
     
    GreyImport, Jan 15, 2014
    #83
  4. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Last edited: Jan 20, 2014
    GreyImport, Jan 20, 2014
    #84
  5. geesex66

    geesex66 Active Member

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    Covers look great Ben. What's you technique for cleaning them? Or where did you find out the technique?

    Also where did you find those instruments? Look very cool
     
    geesex66, Jan 21, 2014
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  6. geesex66

    geesex66 Active Member

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    geesex66, Jan 21, 2014
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  7. Dave H

    Dave H Active Member

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    A good find on the article, it explains why
    the wires on my rec/reg don't match the wiring diagram.
     
    Dave H, Jan 22, 2014
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  8. Ben Mulligan

    Ben Mulligan Well-Known Member Premium Member Contributing Member

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    So the guys at the kustom kommune helped with the technique and there's a video from Mostyn custom bikes in QLD on youtube that explained a lot. http://www.youtube.com/embed/GQvw42...ue&height=370&width=640?autoplay=1&hd=1&rel=0

    Thanks for the article, looks like i'm getting a new one that doesnt need much airflow anyway because its going under the hump.
    NICE! Thanks Grey! I've got a new exhaust on the way from JPN so will need the carb's jetted no doubt
     
    Ben Mulligan, Jan 22, 2014
    #88
  9. Ben Mulligan

    Ben Mulligan Well-Known Member Premium Member Contributing Member

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    She's been de-tabbed and looking super thin now!
     

    Attached Files:

    Ben Mulligan, Jan 22, 2014
    #89
  10. Fox McScrooge

    Fox McScrooge Well-Known Member Premium Member Contributing Member

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    Hi Ben. Read right through your thread. Really impressed with what you are doing mate. It's going to be a great bike.

    I thought I might make a few suggestions. Like Risky, I always use either 304 or 316 stainless fasteners. You can get them for really cheap (like less than 50 bucks for the entire bike with spares left over) at a bolts and fasteners outlet. Best thing is you can get them in Allen Key drive so removing them later isn't an issue. They look good too and don't tarnish.

    For cleaning alloy and leaving it in it's raw state, have you considered Wet Blasting? It's basically a low pressure water blast containing a glass media. The results can be amazing. I recently had the fork sliders done on my NSR and I'm really happy with the result. It's non abrasive so it won't remove scratches, but it burnishes the alloy and makes it shine with a long lasting finish that doesn't need paint. The guy I used is in Brisbane (wetblasting.net) so won't be much use for you but his website has some good info and photos. I know there are shops down your way that do it. I've attached a few photos of my fork sliders for you to take a look at.

    Can't wait to see the end product mate.

    Cheers
    Jim

    IMAG0171.jpg IMAG0172.jpg
     
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    Fox McScrooge, Jan 22, 2014
    #90
  11. Ben Mulligan

    Ben Mulligan Well-Known Member Premium Member Contributing Member

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    Thanks Jim,

    Fasteners/bolts were anodised aluminium black in the end and I picked them up for about $55. I used a copper grease and got good quality ones so that they wont have a problem in the threads or with heat. I would've gone stainless if I had double the budget, and you know, it saves SO much weight :p

    So the engine is finally painted and the heads are back on after meticulous taping and painting. Glad I opened the sump up as there was some nasty plastic caught in the sump filter. Cleaned that out nice and did it all back up. Also a special box arrived from the land of the rising sun!!!! KSY Exhaust. Bam. Now I can start thinking about jet sizes and putting it back together

    Last thing, the rear sets I chose from loaded gun customs in the US are bogged down in the shitty snow in Chiraq, IL since the 27th. I'll just have to be patient before welding can commence on tail and rearsets. But I'm having a seat pan made up that will hold my 85kg ass and the battery and electrics underneath.

    PHOTOS

    IMG_3395.jpg IMG_3396.jpg IMG_3398.jpg IMG_3413.jpg IMG_3416.jpg IMG_3417.jpg
     
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    Ben Mulligan, Jan 30, 2014
    #91
  12. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Love that exhaust!

    can u link me to where u got it? :D
     
    GreyImport, Jan 30, 2014
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  13. Ben Mulligan

    Ben Mulligan Well-Known Member Premium Member Contributing Member

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    Ben Mulligan, Jan 30, 2014
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  14. Phil

    Phil Senior Member Contributing Member

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    Some pretty serious progress going on there Ben. Engine looks awesome, as Grey said the exhaust is sweet, can't wait to see some final pictures of it all back together, well done mate.:thumb_ups:
     
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    Phil, Jan 31, 2014
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  15. Ben Mulligan

    Ben Mulligan Well-Known Member Premium Member Contributing Member

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    U . S . A . U . S . A

    Jus' kidding.

    IMG_3462.jpg IMG_3463.jpg
     
    Ben Mulligan, Feb 4, 2014
    #95
  16. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    I want some gold ones :D
     
    GreyImport, Feb 4, 2014
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  17. Ben Mulligan

    Ben Mulligan Well-Known Member Premium Member Contributing Member

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    IMG_3528.jpg Hey Team,

    Progress on the build whilst the welder makes the custom plates for my rear sets. I mocked up the majority of the bike so I could get the position right and it gave me a hint of what it will look like. What do you think?

    Its already been suggested to do a slight tank raise at the back which I might do but I don't want to interrupt fuel flow as the tank is tilted back (I assume) to get the last of the dregs out when you are low.
     
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    Ben Mulligan, Feb 11, 2014
    #97
  18. kiffsta

    kiffsta Senior Member

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    Looks killer, I agree on the tank raise as it lines it up with the café seat, it would be about 10mm ?
     
    kiffsta, Feb 11, 2014
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  19. Ben Mulligan

    Ben Mulligan Well-Known Member Premium Member Contributing Member

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    Yeah 10-15mm, i'm thinking of doing it with some weld
     
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    Ben Mulligan, Feb 11, 2014
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  20. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Looks fantastic !

    For the sake of maybe a few drops of fuel I would definately raise the tank .... much cleaner line.
     
    GreyImport, Feb 11, 2014
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