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Old August 15th, 2022, 10:46 PM   #1
CZroe
CPT Falcon
 
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Name: J.Emmett Turner
Location: Newnan, GA
Join Date: Apr 2009

Motorcycle(s): '08 CP Blue EX250J, '97 unpainted EX250F, 2nd '97 unpainted EX250F (no engine), '07 black EX250F

Posts: A lot.
Bike sat years. Overhaul time. What’s first?

Edit - It’s a build log now… Part 1:
https://imgur.com/a/bivUW24
…and Part 2:
https://imgur.com/a/QheZ6Qt

You can follow here or the IMGUR galleries. The galleries include video and other pics not posted to the thread directly.



https://i.imgur.com/SaW2tGE.jpg

My 2008 has been sitting, unattended, for several years. It’s been under a cover and up on stands since 2012 but it still got absolutely filthy.


https://i.imgur.com/GdI5mkp.jpg

This chain has zero miles but is still rusted and covered with mud. Like the Sportisi undertail, even the cover is rotting.


https://i.imgur.com/ldAPunn.jpg

The battery has zero miles too, but it hasn’t been tended since 2015 so I went ahead and bought another. Though it was running when I parked it I know it’s going to need a lot more than just a battery before I even try to start it. I need a plan of action before I move forward.

I had filled the tank with ethanol free gas and Sea Foam before it sat, so at least there’s that. I don’t recall if I ran the carbs dry the last time since I was occasionally starting it up every few months. I recall it was very difficult the last time so I let it run hours until the Sea Foam worked its magic. Hopefully that didn’t make too much room for rust at the top of the tank.

I emptied the tank a couple times to replace a leaky petcock but the last time was over 7 years ago but it’s still the same fuel from ~9 years ago. The leaky petcock was filling the carbs up and probably getting down in the crank, which is why I stopped running it (needed to change the oil again after discovering the leaky petcock and never did).

I last used Shell Rotella T6 Full Synthetic oil after parking it and smelling gas in the oil but that’s many years old now so it’ll need changing. I still have unopened jugs of the stuff from before the last oil change but it’s obviously just as old. Do I need to throw all that out? Hopefully the replacement petcock didn’t develop the same issue since I suspect a common factory defect but I’ll be doing another oil change before I try to start it.

So, part of the reason it was parked was because I was hearing cam chain noise and I wanted to do a valve inspection/adjustment. I also removed the forks to replace the seals and never put them back, so they’ve actually been stored in a better place most of this time. Unfortunately, some parts were moved and improperly stored by a family member, ruining the headlight so I bought HID projectors and a Koso gauge during the forum group buy (yes, it was that long ago).

At some point I stripped the threads for the cam chain tensioner cap and don’t recall if I ever properly sealed it off so it may have formed an unwanted breather hole into the crank case. I figure I still need to do that valve inspection so I can look for any issues while I’m figuring that out.

Next, since I’m worried about fuel, water, or rust in the combustion chamber I guess I should not try to turn the engine over without checking the condition of the cylinders and piston heads. I assume I have to remove spark plugs but I still have no way to peek down into there. Do they rent or loan inspection cameras at auto parts stores? If I see any of those things I assume it’s time for a new engine since I don’t know what to do about them.

I’m sure the air box is full of spiders or worse by now. I’ll need to clean that out and replace the filter too. I don’t think I should even try to start it without removing and cleaning the carbs with a rebuild kit. Might make checking the pistons/cylinders easier too.

So, obviously, there’s a lot to do before I can even start it up and even more to do before I can ride it (rusted chain, old/dry tires, service brakes, etc). I’ve never been mechanically inclined but this bike is nowhere near the point where I could wheel it in to a dealer for service. Casey, a former forum member, and I did perform a valve service back in 2011 but I was just the one holding the camera and handing him wrenches and stuff. Unfortunately, Casey flamed out, deleting his valve service video and all his posts. Still, that experience along with this guy’s excellent video gives me renewed confidence for doing it myself:
https://youtu.be/MP0kYpdZclU

Casey: You’re still appreciated!

Not counting my unfinished mods (gauge, HID projectors, etc), so far:
Replace battery
Check tank for rust
Check petcock
Replace fuel
Clean out air box
Replace air filter element
Drain engine oil
Drain coolant
Rebuild carbs
Replace spark plugs
Perform valve inspection/adjustment
Replace cam chain tensioner
Replace oil/coolant/filter
Attempt start
Sync carbs
Replace chain
Rebuild/bleed brakes
Replace tires
Check/lubricate bearings
Tension/align chain
Ride?

Anything missing or out of order for getting this mothballed bike back up and running? I imagine I probably need to do some of that stuff that almost never gets done… like swingarm service, since being technically off the ground didn’t really keep the ground off... if you know what I mean.


https://i.imgur.com/yyJ4hie.jpg

I still have all the plastics and Sportisi hugger around somewhere though I’ll probably find I’m missing lots of bolts/hardware. Perhaps I should order a set of replacement bolts/hardware before I begin. Any suggestions? I almost lost another when I was trying to get pics and who even knows where the rest are.


https://i.imgur.com/Rgr1Imt.jpg

I do want to point out that this Lockhart-Philips triple tree stand has really taken my abuse well. They sent it to me many years ago after an older design without gusseting at the neck failed. I wasn’t even the original owner. No doubt, even a ladder with a ratchet strap would’ve failed by now… especially since I wouldn’t have been able to fit the cover. This thing is rock-solid and it’s great to know that they support their products!

Last futzed with by CZroe; August 30th, 2022 at 08:38 AM.
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