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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. CobraBaz

    CobraBaz Member Premium Member

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    Yep slowly putting together as we speak jus lookin at which way cams go now lol,,,,,
    I`m Jus gona build it as is for now as both engines seemed to be good condition donor had warranty and Cobra was runner until my pal bumped it so hoping for a bit of luck on my side,,,,
    measured all valve shims off Cobra head and all between 150 -160
    Im not at all bothered about pullin it apart again lol quite Im enjoying it, nice bike for a project :)


    IMG_20210219_185038.jpg IMG_20210219_185426.jpg IMG_20210219_195050.jpg
     
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  2. CobraBaz

    CobraBaz Member Premium Member

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    IMG_20210219_234717.jpg IMG_20210219_234726.jpg IMG_20210219_234733.jpg
    Here where I'm up to for now,,,,
    Giving up for the night ;)
    After reading n messing I think I got the timing right so I'll oil up the journals and clamp them up tommorow, all markings in line at TDC ,,,,, ordered a smaller torque wrench to the one I got is a bit big for what needed,,,,
    I measured all valve shims and all within 150 to 160 with my vernier .
    More updates tommorow ;)
     
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  3. Andych

    Andych Senior Member Premium Member

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    Ummm your pics are very hard to get good definition on but you cant have that sort of slack on the Cam chain when lining up timing marks... Ideally you should already have the cams bolted down and have measured all your valve clearances...set them accordingly with correct shims (to the biggest gap within specs) and then worry about setting the cam timing.
     
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  4. CobraBaz

    CobraBaz Member Premium Member

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    I am just trying to understand how it all marks up for now,, 1 & 4 at TDC,,, marks on end of cams level,,,, 16 teeth between cog marks ect
    Valves im looking at today before anything else,, its all learning for me m8 :)
     
  5. CobraBaz

    CobraBaz Member Premium Member

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    Engine now rebuilt,,, checked valves,,,,, all seem to be within specs,,,, timed up to all marks,,, turned engine over by hand many times to check all runs free......
    Fingers crossed Ive done it right,,,, I followed the Across manual from files for torques timing ect :s
    Next job is to give carbs a quick clean out,,,, they dont look bad at all then hopefully get engine back in tomorrow :)
    Upto now its not been to hard of a task although a bit daunting at times,,,, Spendin around £500 on an engine then pullin it to bits is not what I normally call fun But hey its better than spending it on beer :p
    Fingers Crossed!!!
    Just checked Carbs an they was spotless inside,,,, my pal did say he drained them when he stored it ;)
     
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    Last edited: Feb 21, 2021
  6. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    Sounds like your making good progress m8..check and re check everything as you go - valve clearance is 0.17-0.27 in, 0.2-0.3 ex..I always aim for the the bottom end of the range but I do tend to adjust more often..shims are available in .025 sizes if needed rather than the .05 norm - give us a shout if needed as i've got a fair fair few..your only looking at about 2 hp between the top and bottom of the clearance ranges but every little helps :) If you intend to leave it 5K miles plus then go for the top end of the range as the inlets will close up if you use the revs..be careful not to overtorque anything - that across manual will suffice so you needn't worry - be careful when reattaching the exhaust and go little by little with the bolts as there easy to strip the threads..if the carbs are clean then clean again..pay particular attention to check the 'merge chamber' as its a big issue with these bike's when they've been stored (see @maelstroms bdst carb guide as he's got some super clear pics)..also don't overtighten the brass nut on the jet housing :)..go with a bench sync once done so you've got a baseline to start from..cooling and electrics next..!
     
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  7. CobraBaz

    CobraBaz Member Premium Member

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    Its going in anyway but it feckin hard work on my own,,,,,,,,
    Got Gym to help :)


    IMG_20210221_145659.jpg IMG_20210221_145622.jpg
     
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  8. CobraBaz

    CobraBaz Member Premium Member

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    IMG-20210221-WA0003.jpeg IMG_20210221_220428.jpg
    Engine in but removed head top for final check of valves and job I've done off a m8 before I try fire her up tomorrow ;)
    Fingers crossed :)
     
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  9. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    Good luck pal..fingers crossed for yus!!! :):):) get some sleep now..:)
     
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  10. CobraBaz

    CobraBaz Member Premium Member

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    Not had proper sleep for bout 5 week m8,,, its all dreams about engines pistons valves ect and the money i keep throwin at it lol
    But i feel like ive learned loads,,,, first time i heard of a valve shim 3 of the buggers landed on my lap 3 days ago haha
    Love it ,,, :p
     
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  11. CobraBaz

    CobraBaz Member Premium Member

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    Hi people
    Well Im happy to say with finding this site and lots of priceless help from Simon,,,,,,,,
    The Cobra is ALIVE!!!!!!!!!
    Jus needed a decent charge in my Battery off my lil Bobber and a tiny squirt of Starter fluid,,,,, after a lil cough n splutter she screamed at me at 7:30 this mornin :)
    Had it running up to temp,, fans working and starts off the button instantly,,,,
    Im propper chuffed as i aint no mechanic jus learning only done a 125 piston change once before!!!!
    Ive jus tried to set up a youtube page ,,,,,
    Heres a little vid of second start up

     
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  12. CobraBaz

    CobraBaz Member Premium Member

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    153373764_10157935029008977_9005117724203982060_n.jpg 154413268_10157935028998977_3913716113467442783_n (1).jpg
    Little clean and clothes back on :)
    I love this Bike :p
     
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  13. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    Great work fella!!!!! I'm propper chuffed now its running..steep learning curve being the first four stroke and first four cylinder you ever worked on but rebuilding an engine from the crankcase up is no mean feat..god help the neighbours if that's in the front room this morning!!!! I told yus they sound a bit unique!!! Mixture screws need to be richened up a tad as the revs are hanging (slow to drop to idle), do it in 1/8 turn measurements, out or 'anticlockwise' away from being seated. You usually do it by ear but if you do it the way above, stop going any further when the revs just start to drop below idle as the throttle is snapped shut before rising to a steady idle again. Then turn them back in an 1/8 th of a turn - you'll be about there. It'll rev more freely and drop to idle much faster..ur welcome to bring it round after lockdown ends and set them up one by one, cylinder by cylinder with the innovate attached - the ports are already on the down pipes so its attach and go :) what a difference a week makes pal..not a beginner anymore :) no thanks needed for any help m8, you did all the work..bet your lads hooked now too! These bikes are rare - i'd say the cobra even more so than the gsxr its based on..and its got a replaceable flywheel to boot!!!! Well done m8 credit and kudos where due :):):) many would have backed out or not started at all :) Thats another 250 resurected..if they still made them youngsters would be hooked!!
     
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  14. CobraBaz

    CobraBaz Member Premium Member

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    Im made up with it ,,, its sat at the side of me lookin great,,, jus need to service brakes and sort them lil rubber bolt things off radiator and source a rear light ( mine was lost in the 10 year or so it was in bits in shed lol)
    then off for mot :)
    Ill deffo call once i got it sorted m8,,, be nice to meet my Mentor lol
    gota finish this lil bobber now,, it got threw to the side in bits once i got this back haha
     
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  15. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    will see what I've got up at the unit this weekend fella - is it just the light glass, light glass and light unit, or the light complete with the backing plate..will probably have all but can't promise until i've had a good look - the rubber bolts are known as 'radiator cushion bolts' and are the same part used on the rm 125 and rm250 :) they'll be on ebay somewhere or pay an arm and a leg for some direct from japan..lockdown ends the first beers on me :) daughters had their second dose of the pfizer jab today..all bar the youngest and me are done now so bring on spring and some freedom..haven't been out on two wheels since the October firebreak last year :help:..think about those tyres before you go gung ho!!!!!! bike looks like a gem in the front room..I've shown the misses the pic but got a look that's akin to 'you wont ask' as the answer :)
     
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  16. CobraBaz

    CobraBaz Member Premium Member

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    I think its the complete light and bracket ill take a pic later and show ya,,,,,,
    need to get a rear disc and pads and pads for front to,,,,,
    And order a battery this week,,,,,
    Apart from that i think im jus gona clean re-grease bearings ect at leisure and get a bit more polish on it :p
    a couple of fairing plastic studs are missing is there anyway to fix these,,,,,
    Apart from that m8 she is and looks fantastic really pics dont do it justice,,,,,
    Look forward to meetin up m8
    thanks again,,,
     
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  17. CobraBaz

    CobraBaz Member Premium Member

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    Was Just checking over things hoping for a little test run tomorrow when battery arrives and noticed a few rust spots inside the tank :)
    Anyway a problem solved is a lesson learned so gonna have a try at electrolysis tomorrow and have a go at gettin rid of it :)
     
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  18. CobraBaz

    CobraBaz Member Premium Member

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    152382946_425029911909298_841667640912147290_n.jpg 154965454_141573684491669_5580082723787202429_n.jpg 151235982_441692150963722_6251144412789343569_n.jpg 153525488_5339135162824103_5328864364593513153_n.jpg 154963348_144518040771870_5444652751083824457_n.jpg 154786793_148899530386538_3920334544982801025_n.jpg

    After finding some rust spots in my tank last night ,i inspected more today .
    Swilled out my fuel tank with a chain in the tank and a liter of fuel,,,,,,it came out like orange/brown sludge :(
    Was so happy i didnt rush,, fuel up and run that crap through my carbs,,,,,,
    Anyway after speakin to Simon who i can not praise enough,,, he mentioned electrolysis ,
    So after havin a read an gettin a few bits together,, here goes :)
    I think im gona do this and wash out a few times overn next couple of days ,,
     
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  19. CobraBaz

    CobraBaz Member Premium Member

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    Postman just been to :) IMG_20210226_155157.jpg
     
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  20. CobraBaz

    CobraBaz Member Premium Member

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    I think it's working ;)
     

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