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Project My 96 Suzuki Across

Discussion in 'Your 250cc Projects' started by murdman87, Jan 6, 2016.

  1. Phil

    Phil Senior Member Contributing Member

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    Firm is generally still OK, it's when they go rock hard you can encounter problems. Fingers crossed that all goes well.
     
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  2. Murdo

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

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    Is there an O ring around the seat? These can sometimes leak too.
     
  3. murdman87

    murdman87 Well-Known Member

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    Well, while I was putting everything back together, the choke plunger let go of its spring and went shooting off into the distance somewhere. Guess I'll make a trip to my local suzuki dealer and see what they can do for me tomorrow if they are open.
    So no more updates for today I guess.
     
  4. kiffsta

    kiffsta Senior Member

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    Been there, done that. If you get stuck, I have a spare
     
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  5. murdman87

    murdman87 Well-Known Member

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    The new choke plunger arrived in the mail today along with a new oil filter.
    One thing that has me worried is the new choke plunger appears to be plastic, where the old one was brass. I hope this won't affect the bike? I only ordered one since I only lost one, but now it appears I'll have two different types in the carbs :-/
     
  6. kiffsta

    kiffsta Senior Member

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    All the ones I have seen are plastic
     
  7. murdman87

    murdman87 Well-Known Member

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    hmm that's strange.
    Either way, the bike did start up (although it took the help of a can of "start ya bastard").
    Still not running right though. It looks like I'll have to take it to a mechanic, I'm about at the limit of my mechanical know-how.
     
  8. murdman87

    murdman87 Well-Known Member

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    I think the plan is to set the jet needle back to factory and see how that goes. It was set one notch leaner than factory I'm assuming to try compensate for the float being way off spec and flooding the carb.
    So I'll set everything to factory, fresh fuel in (maybe with some carb cleaner stuff? Is there a good brand to look out for?) and get my mate to take it for a spin and see how it goes.
    Wish I had my licence now lol
     
  9. murdman87

    murdman87 Well-Known Member

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    I still cant get the bike to start without using a can of "start ya bastard".
    once it is started the first time it will fire again without it but its the initial start each time just wont happen. any ideas guys?
    responds well to throttle once warmed up although it is slow to return to idle. i read that means vacuum leak but i checked the vacuum lines and they looked good.
     
  10. kiffsta

    kiffsta Senior Member

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    maybe back out your air\ fuel mix screws by 1/8th of a turn

    they should be set 1.5 turns out, you can wind yours in and count them as you go, then back them out 1.5 turns.

    16473-1bb79e5d1e842ec7f4dfcb7a253351cb.jpg
     
  11. Murdo

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

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    Are you sure the chokes are working?
     
  12. murdman87

    murdman87 Well-Known Member

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    I set them at 1.5 when I set the float levels. Bike was very unresponsive and I set it by ear for each cylinder but I think they are out too far to be considered good.
    Going to compression test the motor when I get an hour without rain. (I read on the internet somewhere that needing the screw too far out means you have low compression)

    Not entirely. When warmed up if I apply the choke it sputters and dies, so I guess it does something in there..?


    While I'm posting, I'd like to say thank you to everyone here for all the help with this. I'm sure it's frustrating trying to explain simple things to somebody with no mechanical knowledge.
    Thanks for all the pointers and instructions guys. I really appreciate it.
     
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  13. murdman87

    murdman87 Well-Known Member

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    managed to get a compression test in just as the rain hit.

    my results are as follows:

    cyl 1 2 3 4
    dry 145 135 132 130
    wet 190 210 200 200


    [​IMG]

    so im low on compression. thoroughly disappointed.
    is it worth putting new rings in or is this something that will just cost more than the bike is worth?
    is changing the rings a hard thing to do? rough cost?
     
  14. murdman87

    murdman87 Well-Known Member

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    I've pretty much decided that I am going to rebuild it. I got the bike cheap enough that i knew I'd be spending money to fix something anyway, plus it will be a good learning experience for me.
    So to carry on with the build of my bike, I spent the morning putting some new levers on.
    adjustable anodised shorty levers off ebay.
    You will also notice the el-cheapo bar ends I threw on the other day.


    Before:
    [​IMG]

    After:
    [​IMG]

    Close up:
    [​IMG]

    I think they look sweet, and great value.
     
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  15. kiffsta

    kiffsta Senior Member

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    How are you doing your compression test ? Did you have the carbies off ? Or holding the throttle open full ?
     
  16. murdman87

    murdman87 Well-Known Member

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    throttle wide open.
    I don't think I was very consistent with the amount of oil I used for the wet test though.
     
  17. kiffsta

    kiffsta Senior Member

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    how long did you crank it for ? A failure of your head gasket or excess carbon around your valves \ Cylinder head could reduce your compression, its not always "rings"
     
  18. murdman87

    murdman87 Well-Known Member

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    I kept it cranking until the pressure stopped rising.
    and I was lead to believe that if the oil made a significant difference on the wet test then it meant rings were the culprit.

    to check for carbon buildup id have to take the head off anyway wouldnt I? or is there an easy way?
    i did put a bottle of carby cleaner / buildup remover in the tank when i filled it.
     
  19. Murdo

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

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    Before you pull it apart, get the engine hot and take off the air box lid. Using a plant sprayer, hold the engine at about 4,000rpm and spray a mist of water into each carb. The cold water hitting the hot carbon will cause it to shrink and fall off the piston/cylinder head/valves and go out the exhaust pipe. Keep spraying until you hear a change of engine note and steam comes from the exhaust pipe. Reassemble the air box and go for a good ride, then do another compression test.
     
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  20. murdman87

    murdman87 Well-Known Member

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    wow never would have thought of doing that. ill give it a try cheers mate
     

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