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Project Bumblebee - Gixxer250

Discussion in 'Your 250cc Projects' started by kiffsta, Feb 14, 2016.

  1. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    I think it could be a bit more serious , 120,20,25 and 140. Will know more on Monday
     
  2. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Measure the clearances before you pull the whole thing apart, see if your compression readings correspond to clearances. Maybe do a leakdown test if you have the equipment to do so.
     
    Last edited: Jul 6, 2018
  3. risky

    risky risky

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    try a shot of oil down each plug hole and retest to see if they improve.

    if goes up could be stuck rings
     
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  4. Frankster

    Frankster See the World before you leave it Staff Member Premium Member Ride and Events Crew

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    Nah, I seem to recall doing a leakdown test on this motor with Chris and confirming the rings are effed. Am I remembering that right?
     
  5. risky

    risky risky

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    hope the bore has not been bellied out.
     
  6. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Not this one frank, she has been at home for a long time, I am assuming it is like the zxr400 where the rings have bound up from sitting. I will get the motor apart on Monday and check the bore , If it is savable, then I might get BK performance to to bore it 1mm oversize and slip some Chinese pistons in. I’d like to get this one sorted for our next ride. If all else fails, I will find an across / bandit 250 engine and use the gsxr250 head on it like @Boydie77 did
     
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    Last edited: Jul 7, 2018
  7. ShaneP

    ShaneP Well-Known Member Premium Member Contributing Member

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    Oh no. If it ran fine before being parked, then sounds like the rings are stuck. Hope you haven't pulled it apart, yet. You could use petrol, wd40, kero or something similar to free them up. Unless the valves are rusted/burnt..
     
  8. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    The engine came apart very easily, it was puzzling as several of the cam retainer bolts were quite loose. The rings were not bound as first thought. The barrels do have wear are very very smooth, I have sent them off to BK performance to be checked and measured to determine if a simple hone or a re-bore is required. I am now pulling the head down to check the valves, I pulled the inlet valves from cylinder 1 and can only assume the previous owner pulled them down before I bought the bike, look how clean they are.

    IMG_5668 (2).JPG IMG_5677 (2).JPG
     
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  9. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Just do the petrol in the port test to see if they are leaking.
     
  10. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    I received some feedback today that the outer 2 pots are just within spec but the inner 2 are out, so it is rebore time.

    I am going to order a set of ahl 0.5 pistons from China
     
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  11. ShaneP

    ShaneP Well-Known Member Premium Member Contributing Member

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    What about an Across cylinders and pistons?
     
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  12. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    My chinesium pistons arrived from China about a week ago, they look the goods.

    I dropped them down to BK Performance to they can be checked and the barrels bored to suit

    Quite excited about the prospect of riding this bike, better order some gaskets !!!
     
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  13. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    Any news buddy???? updates required lol!

    Si
     
  14. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    I should get the barrels back on Friday , I’m itching for it too
     
  15. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    well in anticipation of collecting the barrels, I turned my attention to the head, I had removed several valves to check the condition, I confirmed that someone has definitely been in there and tidied everything up, as per Murdo's advice, I did the fuel down the port test and they valves are sealing really well.

    I went searched for new head and base gaskets, the base gasket was available from Suzuki Australia, but the head gasket was not able to be found. I googled the part number and found some in Japan , the pair delivered were nearly $200 , another google search found some at RGV spares Melbourne, I e-mailed Deet to confirm he had them and he responded right away saying yes he had them in stock.

    genuine Suzuki base and head gasket including postage was $70 , +1 to Deet @ RGVspares.com.au

    The tyres on this bike and well past their used by date, more money... bloody 18" rear
     
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  16. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    The stator cover is looking decidedly average , I have removed it , wet blasted it and have filled the gaps with devcon , will sand and paint on Monday

    B90EFFDB-4567-4E13-8A12-227EB88D60BB.jpeg 0A8A6728-CFAE-4AF9-B2EA-0108FDB0FDD8.jpeg 9164E6A0-53AF-48BD-A273-62C298E39DBB.jpeg
     
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  17. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Went though my tyres this afternoon and found that I don’t have a 130/70 18 Tyre which is standard on the gsxr.

    I did find a 17 “across wheel with a good Tyre and it got me thinking , will this fit ? The rear disk is 210mm on the gsxr and 250mm on the across , the bolt spacing is the same.

    I pulled the gsxr rear wheel off the bike, the wheel itself is slightly skinnier than the across wheel however the sprocket carriers are different as well and even the spacing out. The axle on the gsxr is 20mm and the across axle is 17mm, so I used the across spacers , brake brace , axle and axle adjusters and the wheel fits nicely in the gsxr swingarm, the axle does
    Seem to be 1cm shorter so I need to sort that out.

    The across brake sits on top of the swing arm and the gsxr sits below, so I needed to find something else to use , I ended up using a bandit 250 brake caliper on the across brake bracket and it fits using the 250mm disk

    I’m not a huge fan of changing from stock , but I may have found a cost effective way to use a 17” wheel which opens up my Tyre choices for this bike , I will
    Slip the engine back in shortly to check the Chain alignment

    Here are a few pics of the across wheel, I will check my bandit spares ,
    I’m hoping the bandit axle is 17mm or I might even try a bandit rear wheel

    09FF2C0F-7CA8-46D6-BD34-3BD3760563B7.jpeg C26CA970-164C-438F-9433-32CC42903FC4.jpeg
     
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  18. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    What size is the front @kiffsta ?

    Motorcycle Tyre Warehouse have 130/70/18 in rear tyres, not a great range, but you can get them.

    https://www.motorcycletyrewarehouse.com.au/13070-18

    Maybe a 140/60/18 like the ZXR runs would work?

    Underslung caliper is all about keeping the centre of gravity low, almost every GSXR from that era runs that setup
     

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