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Project My GSX250 build

Discussion in 'Your 250cc Projects' started by samthurtell83, Aug 22, 2021.

  1. samthurtell83

    samthurtell83 Grumpy Dad

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    G'day. I started out with the idea to get a cheap daily. One of my workers had this 82 GSX250 in his yard. A deal was struck and it came home with me. [​IMG][​IMG]

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  2. samthurtell83

    samthurtell83 Grumpy Dad

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    Now I knew it was going to take a bit of work to get back on the road, but I just didn't realise how much.

    This thing was an absolute bucket of puss.
    So, we washed 15 years of crud off it and started stripping it down to see what was needed.

    As it turned out, it needed pretty much everything rebuilt.

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    [​IMG]
     
  3. samthurtell83

    samthurtell83 Grumpy Dad

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    I got on the internet thing and ordered a heap of parts. New tank bushes & bolts, a Motogadget m-unit blue, new wiring to suit the m-unit, new switchgear, mirrors, battery, carb kits etc.

    I stripped down the bike and started removing all the unnecessary or broken parts. Today I managed to shave the rear mudguard, shaved the frame, made an electronics tray and drilled holes ready for mounting the electronics. [​IMG][​IMG][​IMG][​IMG][​IMG][​IMG][​IMG][​IMG]

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  4. samthurtell83

    samthurtell83 Grumpy Dad

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    Next up is getting some new mounting hardware and battery cable & lugs. Then I'll attack the wiring

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  5. samthurtell83

    samthurtell83 Grumpy Dad

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    Getting stuck in this morning on power and earth cables. [​IMG]

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  6. samthurtell83

    samthurtell83 Grumpy Dad

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    Well I have the wiring all done now apart from the lighting & the dash.

    I've also had the carbies off, disassembled, cleaned & rebuilt. I can get the engine to fire, but that's it. It wont idle, rev out, nothing.

    After going through these carbs three times, I think I may have figured out my issue, missing pilot air jets... How I missed this the first time I just don't know. As for why they aren't fitted, that's another question. Now I need to find a supplier. While I'm at it, I suppose I should also get bigger jets as discussed in the tuning thread.
     
  7. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Why would you need bigger jets?
     
  8. samthurtell83

    samthurtell83 Grumpy Dad

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    The bike has 2into1 exhaust plus pod filters.

    The original airbox was chopped into 3 bits when I got it, so I'm staying with the pod filters.



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  9. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    A 2 into 1 exhaust wont necessarily mean less back pressure etc. it could end up more restrictive depending on how it has been done.
    Pods... meh, good luck with them.
    Generally you will find the better compromise with Pods will be to go down a jet size and try and tune around the flat spots...
    Best bet is to actually get it to run (idle) with the pods on and then see how it goes under load. Do plug checks but you will most likely find big flat spots and running rich.
    If you are going pods, try to get the best quality ones you can.. K&N and see if you can fit velocity stacks as well.
    Pretty much every Japanese bike runs like a dog unless you have the original Air box on there.
    Good luck with it..
     
  10. samthurtell83

    samthurtell83 Grumpy Dad

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    Yeah, I'm aware of the tuning nightmares with CV carbs. I'm happy to spend the time tuning it until it's right. But right now I just need it running.

    I have been eyeing off a pair of Mikuni VM26's though.

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  11. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    You cannot get different needles, slides, nor emulsion tubes for CV carbs. You can get everything for VM's.
     
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