1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

ShammaLamma's GSX250 project

Discussion in 'Your 250cc Projects' started by ShammaLamma, Dec 20, 2013.

  1. ShammaLamma

    ShammaLamma Member

    Messages:
    21
    Likes Received:
    20
    Trophy Points:
    13
    Joined:
    Dec 20, 2013
    Gender:
    Male
    Location:
    Melbourne Australia
    My Bike:
    1983 GSX250
    Yeah that air box is crazy, i got mine out after an hour long struggle
    Pods are less restrictive so the mix becomes leaner meaning you should go with bigger jets, at least that's the theory.

    First post on here because i recently picked up a gsx 250 (same year i think) also, planning a cafe build
    I've cleaned up the starter and the motor turns over, so I think it would run (it was stored outside and is a bit rusted up), but i've got no experience or idea with the electrics and no place to start as the bikes electrics were disconnected from the battery. (all the bikes i've had experience with had magnetos :/ )

    I'd really appreciate any photos of a running electrical setup ( around the battery) or even a wiring diagram ?

    -- When i had the plugs out and connected the starter to turn it over, there was no spark from either plug, is this a fault with the ignitor or coils?, or is it a kind of killswitch feature because the ignition and instruments weren't connected ?

    Thanks in advance

    Tom

    P.S. Sorry for the thread-jack but i searched and this seemed like the best option
     
  2. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

    Messages:
    7,960
    Likes Received:
    5,835
    Trophy Points:
    1,168
    Joined:
    Aug 7, 2010
    Gender:
    Male
    Location:
    Brisbane
    Home Page:
    My Bike:
    90 CBR250RR , 2003 ZXR250 , Suzuki T500, 1989 gsxr250 , 1994 Honda RVF400
    Hey Tom

    No probs mate, I thought this one deserved its own thread, Are you running power to the starter directly or using the switch b I would re-connect your switch blocks as I am almost certain the GSX has a kill switch and this may be why its got no spark. Make sure your grounding the plug on the metal part of the motor( don't hold the plug or lead) use something to insulate yourself or just lean it there.

    I don't have a wiring diagram... but I willing to bet GI is on the prowl for one

    Cheers

    Chris
     
    • Like Like x 1
  3. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

    Messages:
    8,329
    Likes Received:
    4,903
    Trophy Points:
    1,168
    Joined:
    Jun 14, 2012
    Gender:
    Male
    Occupation:
    Troublemaker
    Location:
    North by NW NSW Oztralia - Tamworth
    My Bike:
    *Kawasaki ZXR250C *Yamaha FZR250R 3LN1 *Suzuki GSX250 *Triumph Bonneville 750 T140V
  4. ShammaLamma

    ShammaLamma Member

    Messages:
    21
    Likes Received:
    20
    Trophy Points:
    13
    Joined:
    Dec 20, 2013
    Gender:
    Male
    Location:
    Melbourne Australia
    My Bike:
    1983 GSX250
    I wasnt running through the switch blocks cause i didnt want to wire them up wrong and fry somthing,
    but the plugs were grounded and i've heard enough stories about getting zapped to be careful :D
    good to know that it probably has a killswitch, give me hope that i wont have to replace too much


    Thanks a bunch, i had a PDF manual but it wasnt very detailed(much earlier model too) ,
    i'd seen that one on ebay and had thought about buying it , good thing i didn't :D
     
    • Like Like x 1
  5. ShammaLamma

    ShammaLamma Member

    Messages:
    21
    Likes Received:
    20
    Trophy Points:
    13
    Joined:
    Dec 20, 2013
    Gender:
    Male
    Location:
    Melbourne Australia
    My Bike:
    1983 GSX250
    I've still been trying with this but it seems that every time i try to download more than one part of the manual the website goes down (for me only ?) for 2-3 days!
    So i've only got the first 3 parts so far
    Can anyone shed some light on this ?

    In an effort to make some progress, i've found a full wiring diagram for the gs400 (similar year)
    and it appears to be almost identical, (some switch block differences)
    So i hope to sort out these electrical gremlins soon.

    On a side note , does anyone know of an aftermarket gas cap for the GSX tank ?
    the key didnt work in it and it broke as i was trying to get it out
    Im not devastated as its not the best looking cap.

    Thanks in advance
    -Tom
     
  6. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

    Messages:
    8,329
    Likes Received:
    4,903
    Trophy Points:
    1,168
    Joined:
    Jun 14, 2012
    Gender:
    Male
    Occupation:
    Troublemaker
    Location:
    North by NW NSW Oztralia - Tamworth
    My Bike:
    *Kawasaki ZXR250C *Yamaha FZR250R 3LN1 *Suzuki GSX250 *Triumph Bonneville 750 T140V
    What I found with my cap is the key will only go in half way kinda thing but still works the lock ..... actually a screw driver will open it so theres probably half a key broken off inside ...... eventually I will try to pull it apart and take a look.

    I had a quick search for a replacement/aftermarket cap but couldnt find anything ..... as can be seen in my GSX thread I found the one I have is perfect for my black and gold theme and fits the 400 tank I bought also.

    Heres a link to my google drive to access the manuals .....

    https://drive.google.com/folderview?id=0ByHbiu0yM2SGd3BqU3BqSnMzeE0&usp=sharing
     
    Last edited: Jan 13, 2014
  7. ShammaLamma

    ShammaLamma Member

    Messages:
    21
    Likes Received:
    20
    Trophy Points:
    13
    Joined:
    Dec 20, 2013
    Gender:
    Male
    Location:
    Melbourne Australia
    My Bike:
    1983 GSX250
    GI thanks Soooo much for the manuals :D
    Progress is happening slowly, checked the killswitch and the starter button , all clear,
    [​IMG]
    A new coil to replace a broken one, new front brake line to replace the old one that had cracked right through
    (also by "new" i mean "from the wreckers down the road" :p )
    Tomorrows plan is to wire up a new battery, try the starter and see if she sparks, if so its back down to the wreckers for a pair of headers to see if it runs !
     
    • Like Like x 2
  8. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

    Messages:
    8,329
    Likes Received:
    4,903
    Trophy Points:
    1,168
    Joined:
    Jun 14, 2012
    Gender:
    Male
    Occupation:
    Troublemaker
    Location:
    North by NW NSW Oztralia - Tamworth
    My Bike:
    *Kawasaki ZXR250C *Yamaha FZR250R 3LN1 *Suzuki GSX250 *Triumph Bonneville 750 T140V
    Hey how much did u pay for the coil?
     
  9. ShammaLamma

    ShammaLamma Member

    Messages:
    21
    Likes Received:
    20
    Trophy Points:
    13
    Joined:
    Dec 20, 2013
    Gender:
    Male
    Location:
    Melbourne Australia
    My Bike:
    1983 GSX250
    $25, i saw you were looking for some in your other thread, i think they have at least one more
     
    • Like Like x 1
  10. ShammaLamma

    ShammaLamma Member

    Messages:
    21
    Likes Received:
    20
    Trophy Points:
    13
    Joined:
    Dec 20, 2013
    Gender:
    Male
    Location:
    Melbourne Australia
    My Bike:
    1983 GSX250
    Great news, :D
    Finally wired in a battery, starter button works, i put in the new coil and i was shattered at first , no spark but i took the cap off trimmed the lead and it worked !
    splash of fuel in the plug holes, just to see if it would fire, resulted in only small flames out of the exhaust ports

    Next step: Buy headers and hook up the tank :D
     
    • Like Like x 3
  11. Phil

    Phil Senior Member Premium Member Contributing Member

    Messages:
    3,618
    Likes Received:
    1,550
    Trophy Points:
    923
    Joined:
    Aug 8, 2010
    Gender:
    Male
    Occupation:
    M C E
    Location:
    Sunshine Coast Qld
    Home Page:
    My Bike:
    Suzuki GT250X7 Kawasaki ZZR600
    Well done mate, sounds like you're nearly there. Back down to the wreckers for the headers and you should have that bad boy all fired up. Keep us posted.
     
    • Like Like x 1
  12. ShammaLamma

    ShammaLamma Member

    Messages:
    21
    Likes Received:
    20
    Trophy Points:
    13
    Joined:
    Dec 20, 2013
    Gender:
    Male
    Location:
    Melbourne Australia
    My Bike:
    1983 GSX250
    Headers are on, Problems with the starter have been fixed again, tried to fire it up but no go, ill pick up some new plugs tomorrow ( i think i read that D8EA cane stock in the US can anyone confirm?) and maybe some Start-ya-bastard or something of the sort

    Im having trouble with the lines off the carbies and all the hoses had been cut or removed before i got it
    obviously the one with the T-piece goes to the fuel,
    i know another one must go to the petcock valve (which one ? ) and another is an over flow ?

    P.S. i can't look at the bike atm to check if there are only 3 lines coming off the carbies, am i right in that assumption ??

    Thanks for all your help guys
     
  13. ShammaLamma

    ShammaLamma Member

    Messages:
    21
    Likes Received:
    20
    Trophy Points:
    13
    Joined:
    Dec 20, 2013
    Gender:
    Male
    Location:
    Melbourne Australia
    My Bike:
    1983 GSX250
    ^^ P.P.S. Picked up a new chrome tank cap off ebay for $30 inc.p/h not OEM but better looking and fitting IMO.
    Listed under "SUZUKI DS125 GN400 GS450 GS750 SP370 TS100 TS125 TS185 TS250 CAP" for those interested :)
     
    • Like Like x 1
  14. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

    Messages:
    8,329
    Likes Received:
    4,903
    Trophy Points:
    1,168
    Joined:
    Jun 14, 2012
    Gender:
    Male
    Occupation:
    Troublemaker
    Location:
    North by NW NSW Oztralia - Tamworth
    My Bike:
    *Kawasaki ZXR250C *Yamaha FZR250R 3LN1 *Suzuki GSX250 *Triumph Bonneville 750 T140V
  15. ShammaLamma

    ShammaLamma Member

    Messages:
    21
    Likes Received:
    20
    Trophy Points:
    13
    Joined:
    Dec 20, 2013
    Gender:
    Male
    Location:
    Melbourne Australia
    My Bike:
    1983 GSX250
    • Like Like x 1
  16. ShammaLamma

    ShammaLamma Member

    Messages:
    21
    Likes Received:
    20
    Trophy Points:
    13
    Joined:
    Dec 20, 2013
    Gender:
    Male
    Location:
    Melbourne Australia
    My Bike:
    1983 GSX250
    [​IMG]

    The tank in high build undercoat.
    Still needs some sanding but looking pretty good with the new cap
    :)
     
    • Like Like x 3
  17. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

    Messages:
    8,329
    Likes Received:
    4,903
    Trophy Points:
    1,168
    Joined:
    Jun 14, 2012
    Gender:
    Male
    Occupation:
    Troublemaker
    Location:
    North by NW NSW Oztralia - Tamworth
    My Bike:
    *Kawasaki ZXR250C *Yamaha FZR250R 3LN1 *Suzuki GSX250 *Triumph Bonneville 750 T140V
    Does look good! :thumb_ups:
     
    • Like Like x 1
  18. Phil

    Phil Senior Member Premium Member Contributing Member

    Messages:
    3,618
    Likes Received:
    1,550
    Trophy Points:
    923
    Joined:
    Aug 8, 2010
    Gender:
    Male
    Occupation:
    M C E
    Location:
    Sunshine Coast Qld
    Home Page:
    My Bike:
    Suzuki GT250X7 Kawasaki ZZR600
    If that is the undercoat, can't wait to see the finished product, looking good.:thumb_ups:
     
    • Like Like x 1
  19. ShammaLamma

    ShammaLamma Member

    Messages:
    21
    Likes Received:
    20
    Trophy Points:
    13
    Joined:
    Dec 20, 2013
    Gender:
    Male
    Location:
    Melbourne Australia
    My Bike:
    1983 GSX250
    Metalflake samples came in :)
    Ill be getting some clear coat and silver paint on monday to begin colour testing...
    [​IMG]
     
  20. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

    Messages:
    8,329
    Likes Received:
    4,903
    Trophy Points:
    1,168
    Joined:
    Jun 14, 2012
    Gender:
    Male
    Occupation:
    Troublemaker
    Location:
    North by NW NSW Oztralia - Tamworth
    My Bike:
    *Kawasaki ZXR250C *Yamaha FZR250R 3LN1 *Suzuki GSX250 *Triumph Bonneville 750 T140V
    Looking forward to seeing the results! :thumb_ups:
     
    • Like Like x 1

Share This Page