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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. Simon

    Simon Well-Known Member Premium Member Contributing Member

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  2. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    The shiny bit - remodel over a larger area to assist 'easing' the pistons into the barrels :)
     
  3. Simon

    Simon Well-Known Member Premium Member Contributing Member

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  4. CobraBaz

    CobraBaz Well-Known Member

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    is this one that has been done?
    i seem to remember a cbr125 i did was like that already from new , i fully understand how it would help thanks :)
     
  5. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    Aim for 70 deg plus angle and about 7mm and you will be fine..basic tip but I bet there's several engine builders that nagged a ring when rebuilding this engine..if you have any q's then just ask as time invested getting it right before hand is time well spent :)
     
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  6. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    That's one that's increased about a quarter..same principle and common to many bikes..suzuki just made this cylinder one a bit 'short' and not nearly staggered enough..fantastic if you have there specialist tool (£450 or aus about $800) but I dont lol..easier to modify it with an hours labour and have it slide straight in :)
     
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  7. CobraBaz

    CobraBaz Well-Known Member

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    yeh cheers m8, deffo things ill remember, i struggle thinkin of anything else at the min haha ive stripped and rebuit it in my head 10 times, browsed many pages on here of simlar bikes and googled allsorts i wish i had the confidence i had now when i first got the bike, it wouldnt of been sat at a shop for ages.
    they have also sent it me back with the starter cogs missing well not impressed ill be on the phone again in the morning,,,,thats the last time anyone works on my bikes!!!!
     
  8. Simon

    Simon Well-Known Member Premium Member Contributing Member

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  9. Simon

    Simon Well-Known Member Premium Member Contributing Member

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  10. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    That's the difference in the starter motors I was on about..I know where the parts came from in the fix lol..not a good garage I might add..or zero experience on these engines..A wont go onto B..I should have a starter 'gear' somewhere in the unit..will have a look and an original starter if needed..where abouts in the UK are you m8..
     
  11. CobraBaz

    CobraBaz Well-Known Member

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    im in oldham manchester m8,,,
    whats that ya know of the garage that never fixed mine lol if they dont sort out my missing parts im gona be making some noise about it! what things they did do i coulda done myself for way cheaper, and it wouldnt of took 6 month lol,, then had to pay to get my bike back £50 when they say it free collection and delivery minus big and small starter cogs!
    lesson learned i serpose :(
     
  12. CobraBaz

    CobraBaz Well-Known Member

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  13. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    Reasearch done now is time saved later!!!!!! stick with it m8 only about 60 miles away in North Wales..once this lockdown stuff ends will lend a helping hand if requested :):)
     
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  14. CobraBaz

    CobraBaz Well-Known Member

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    Yeh nice one m8,, good to know,, cant wait to get my tools and get involved :)
     
  15. CobraBaz

    CobraBaz Well-Known Member

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    DSCF0291.JPG s-l500.jpg
    Little update bought this engine instead,, had them take pics of flywheel first it is showing signs of ready to crack but should last a while,,, with lil discount i got for £450 delivered so should be here soon.
    Already found New replacement flywheel online about £200ish maybe find cheaper when needed, so factor that into cost with gaskets ect and cost of parts i bought for other engine bikes stands about £1550ish.
    With hopes it will run after this is done ill probably rebuild carbs and then if the Suzuki gods are on my side it should come in at £2000 ish which i will be well pleased with, as its a Very clean bike!
    Thanks to Simon and the rest of you for your help, ill Stick somthing in the Donations pot soon to help with site ;)
     
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  16. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    You'll be up and running in no time m8!!!! feet up and relax now..I can see a few busy weekends coming up for yus..keep us posted pal :):):)
     
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  17. CobraBaz

    CobraBaz Well-Known Member

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    Be a few week before I got some funds for Gaskets n stuff,,,, are they available from uk suppliers probably need both side casing gaskets, head and Base gaskets ,Exhaust gaskets ?
    So for now gona get on with my lil 125 Bobber projects for a while,,, If i can cash one in all the better,,,, but this Bike thing was about makin a few £ and keeping busy over lockdown, now im spendin all my spare ££ and finding It really hard to sell any of them an jus want to keep em all,,,, bit of an Addiction starting lol ;)
     
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  18. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    The stator cover's gasket may be reuseable - if you reuse the gasket a smear of sealant will suffice - dont be tempted not to use a gasket and go with the 'make a gasket' stuff on its own as the clearance wont suffice. Also check that the three stator wires aren't 'pinched' when you bolt it up before you hit the go button, as the routing through the side of the starter motor leads them perilously close to the starter gear. Best advice follow the parts diagram to a tee and you wont have issues. The RHS timing cover doesn't use a gasket as its a dry part. The timing cover on the new engine looks to be a bit bruised - your existing one will bolt straight on. From memory label the screws as they come off as one is a different length to the others. I should have one somewhere if you need one. Base gasket is also a part to be reused (based on time delay in getting one as there only cheap) with another smear of sealant, but if your going top end change only you wont need one as you won't disturb it. I'll deffo have new head/ exhaust gaskets somewhere so if you can't get them without a big delay let me know. Parts are pretty readily available though m8 - any your unsure of just ask ask :) . Now your fully committed(!) I'd order a Litetek carb kit at the earliest available ,(gsxr 250 rk will fit perfectly as there the same carbs) - not sure on how long it will take to arrive - but you WILL need one 100% or it will never run right if at all after being laid up for so long. Best value for money going - quality is top notch- send @maelstrom a message on here as he'll tell you how long it'll take to arrive.
    You can use the time productively over the next week before the new engine arrives by spraying any bolt that might need to be undone with penetrant. Pay particular attention to the waterways that come out through the cam cover as already mentioned - sometimes they require a bit of persuading. I'd set the carbs to one side at this point and treat them as a job on there own. Hook a battery upto your existing motor after you've soaked the bores for a day and checked the crankshaft turns ok. Check for spark at the plugs so you know you have spark (igniter failure is common and coils will be passed there best after 30 years). They may be fine but you can check a lot if you methodically work through it before you start and fix any issues as need be as you go along so it'll go from the off. Time your existing engine to TDC when your done and do the same with the new engine side by side. If your unsure just ask. Take a photo of the signal generator pick up on both and the cam orientation on both at TDC - then take a pic of the camshafts and count the links/pins between the two prior to releasing the camchain tensioner on each. 16 pins from memory. Any problems give us a shout. Take one off (head) and replace with the other after you've checked the gasket surface/head surface for straightness. Rebuild is reverse of disassembly using the new head gasket.

    As you go through just remember to check and recheck. Then check again. Check for ring seal (fill the bores with penetrant and see if any don't hold or are worse than the others. Check the bores for scoring or the dreaded corrosion. Flip the head and do the same to check valve seal - there's not a lot of 'dome' so make one with whatever you have available . I'd look at valve stem seals too as they'll likely be dry/worn out by now due to storage but may be ok - just check and recheck everything - the new engine might have been run as late as november last year from what you say which is only three months ago - ring seal could be perfect!! If in doubt post here as the basics are all the same. Excitement builds this side for yus :):):)
     
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  19. CobraBaz

    CobraBaz Well-Known Member

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    Im gona have a few nights going over the jap manuals ive got with google translate on sons ipad, and ive been reading a few old threads on here, very useful this site :)
    Also might buy these so i can video what i do lol s-l1600 (3).jpg
    only £20
    Good for reference ;)
    Ill keep you updated,,,,, cant wait ,,,,ive got confidence it will live again
    Thanks
     
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  20. CobraBaz

    CobraBaz Well-Known Member

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    Engine should be here by Monday so trying to get my lil bobber finished so can deal with one thing at a time.
    Ordered these recording glasses today with 32G memory card think they be worth it for when stripping engine. Easier than taking photos ;)
    https://www.ebay.co.uk/itm/Mini-HD-...var=503222219156&_trksid=p2057872.m2749.l2649
    I`ve got rotor cover gasket, took 2 almost 2 month to get so will just need head/base and exhaust gaskets as gona strip and inspect bores rings ect before re-building.
    Also Donated $30 to the forum as without finding this i would not of had a clue what i was doing with this bike as info is quite hard to find, @Simon no doubt by the time i get this bike running ill owe you a world of favors or beers when Covid allows :)
    Update to come
    Thanks
     
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