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Help Suzuki GSXR 250 GJ73A Restoration/Rebuild

Discussion in 'Your 250cc Projects' started by Oli, Nov 3, 2014.

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  1. Oli

    Oli Member

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    Hi I am new to this forum and have just purchased a GJ73A a definately need some help working out how to get it together!!! :bowdown::help:

    The bike has been stood for 9 years :oops: and in that time it has been pulled apart in very strange places, it does not run at the moment and the previous owner thinks it was the distributor pick up (see pictures below) there are a few small pieces missing which i hope wont be to hard to find.

    IMG-20141103-00578.jpg IMG-20141103-00579.jpg

    If you guys could point out any missing bits or give any advice that would be great !

    Cheers, Oli


    IMG-20141103-00569.jpg IMG-20141103-00570.jpg IMG-20141103-00571.jpg IMG-20141103-00572.jpg IMG-20141103-00573.jpg IMG-20141103-00574.jpg IMG-20141103-00575.jpg IMG-20141103-00576.jpg IMG-20141103-00577.jpg IMG-20141103-00580.jpg IMG-20141103-00581.jpg IMG-20141103-00582.jpg IMG-20141103-00583.jpg IMG-20141103-00585.jpg IMG-20141103-00586.jpg IMG-20141103-00587.jpg IMG-20141103-00590.jpg IMG-20141103-00592.jpg IMG-20141103-00594.jpg IMG-20141103-00595.jpg IMG-20141103-00597.jpg
     
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    Oli, Nov 3, 2014
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  2. kiffsta

    kiffsta Senior Member

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    That's a great Project Oli, paging @Simon , Simon is in the UK and has access to a workshop manual, he may be able help you source your missing parts

    Cheers

    Chris
     
    kiffsta, Nov 3, 2014
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  3. Oli

    Oli Member

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    Thanks!
     
    Oli, Nov 3, 2014
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  4. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    GreyImport, Nov 3, 2014
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  5. Oli

    Oli Member

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    Yea first thing I did when I got it home was build the fairings and they are in great nic, one split on the belly pan near the gear lever but other than that they just need a good spray !

    Cheers for the links :thumb_ups:

    As for the carbs that seal kit looks great!

    I think I am missing what looks like a vacuum supply hose nipple from the right pair of carbs, just a guess....


    Carb parts 1.jpg

    Ta
     
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    Oli, Nov 3, 2014
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  6. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    GSXR carb.jpg
     
    GreyImport, Nov 3, 2014
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  7. risky

    risky risky

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    welcome and enjoy the project.
     
    risky, Nov 3, 2014
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  8. Oli

    Oli Member

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    So i've circled the bits of carb that I don't have, anyone know where i could get these? I could probably find suitable hose at my local boat builders but have no idea about the other bits CARB EXPLODED DIAGRAM lab.jpg
     
    Oli, Nov 4, 2014
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  9. TechHeadFred

    TechHeadFred Well-Known Member

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    :welcome: Looks like you're well under way!
     
    TechHeadFred, Nov 4, 2014
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  10. zixxer

    zixxer Well-Known Member

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    im not sure if the across has similar carbies or if they are totally different, maybe someone can shed some light on that.
     
    zixxer, Nov 4, 2014
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  11. Oli

    Oli Member

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    Good progress today!! :dance2::drinks:

    Got the sprocket cover off and gave it a clean and worked out why the clutch cable ends up on the opposite side of the bike to the actual clutch, funny little system on this bike.

    Lots of WD40 and many rags were used to get the grime off most of it I pulled out with a flat head

    It was very grotty under there....
    Before........ IMG-20141104-00606.jpg After......... IMG-20141104-00609.jpg

    Gave the case a clean....

    Before.... IMG-20141104-00604.jpg After..... IMG-20141104-00608.jpg IMG-20141104-00607.jpg
    I know there is a spring missing that returns the clutch lever thingy

    Also cleaned out the coolant bottle....


    IMG-20141104-00611.jpg
     
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    Oli, Nov 5, 2014
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  12. tintankaussie

    tintankaussie Well-Known Member

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    Thats the same clutch set-up as my 83 gsx,I got a small but strongish spring and hooked it on where the cable goes into the bracket and the other end to the casing (should be a hole for it) Looking at your pics close up,the speedo stickers with numbers on are for m.p.h.as for the whole job stick with it and tick off your "to do"list as you go along.good job...Ken
     
    tintankaussie, Nov 5, 2014
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  13. Murdo

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

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    :welcome:
    Find the part numbers for the missing bits and google them, sometimes surprises turn up.
     
    Murdo, Nov 6, 2014
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  14. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    How do mate, most of the bits you need are pretty easy to obtain bar the carb cross links..i'll try and point you in the right direction between now and the weekend try nrp carbs for a full rebuild (about £300) to as new standard..if not try them for the parts and attach a microfiche..there pretty much mega..i've got a few spare sets of carbs which I could do much the same on but they'll take a month or so to turn round as i'll need to contact litetek to get the seals I need..trust me there in a different league to the oem stuff in terms of longevity...anything I can do to help then throw us a line,
    cheers si
     
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    Simon, Nov 19, 2014
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  15. Oli

    Oli Member

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    Cheers guys, have not even seen the bike since my last post but have this weekend off so will be cracking on with it then and pay day next week so should see some good progress :D will keep you posted
     
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    Oli, Nov 20, 2014
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  16. monsigna

    monsigna Active Member

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    Hi oli, just read your post. I have just started work on my bike (the earlier GJ72A Model) i may be able to help with part numbers as i have a English version PDF cd. It lists all parts and numbers (usually superceded by equivalents) sadly my bike is the early version with just two carbs to play with, so can't be much help there, if you want any help just ask, you never know. I also run a bike group on Facebook if anyone is interested. It's called B.M.G Bimblers motorcycle group.

    I'm very glad i have found this brilliant group of people, they are very helpful, hopefully if we all pull together, we can resurrect our mini beasts :) all the best, and kind regards, ade. (In the UK)
     
    monsigna, Dec 2, 2014
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  17. Oli

    Oli Member

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    Hellooooo!

    Its been a long time since ive posted....... a very long time but progress has been made and most of it today :D

    So here we go !
     
    Oli, Jan 19, 2015
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  18. Oli

    Oli Member

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    I built a shed for the little beast, with a little help from my friend Tom who owns an fzr250

    She only just fits ;)

    Shed.gif
     
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    Oli, Jan 19, 2015
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  19. Oli

    Oli Member

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    I stripped the coils of the HT leads and caps and fitted new ones...

    HT rebuilt.gif

    Apparently most have moulded caps and leads that you cant remove, so i guess i was lucky that these are the self tapping type
     
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    Oli, Jan 19, 2015
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  20. Oli

    Oli Member

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    Hahaaa on to my allen bolt dilemma...

    The top bolt on cylinder 2 was rounded so I asked around for some tips on how to get it out,
    Allen bolt.jpg

    Most people told me to use an over sized torx bit and hammer it in but on research I found an awesome tool for the job which i highly recommend!
    Irwin.gif

    This little set of sockets 'Irwin Pro Bolt' are great, I attached the smallest one to an extension bar gave it a fair whack with a hammer attached a ratchet and applyed pressure and turned and it came out :) I was worried about snapping the head off or just not being able to get it out and the having to get it re-tapped but this tool realy made light work of the job, if you dont have one get one the set only cost me £25 and contains 5 sizes :D
    Socket.gif

    More to come...
     
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    Oli, Jan 19, 2015
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