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Old December 30th, 2022, 06:31 AM   #81
ducatiman
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@MikeCL is the bike's engine running/starting reliably as yet?
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Old December 30th, 2022, 07:24 AM   #82
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@MikeCL is the bike's engine running/starting reliably as yet?
I will let you know a little later today I have to put fuel in the tank but Iím going to switch the petcock over to the other tank..
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Old December 30th, 2022, 07:27 AM   #83
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The cush drive is sloppy. Often they can be shimmed, but maybe the rubber blocks aren't too expensive. Obviously the chain is shot, and my guess is that the sprockets are too.

Edit: $76+shpg from Partzilla. I might try shimming them with some inner tube rubber.
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Old December 30th, 2022, 07:40 AM   #84
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Quote:
Originally Posted by MikeCL View Post
I will let you know a little later today I have to put fuel in the tank but Iím going to switch the petcock over to the other tank..
THIS (starting/running) should be your first and primary focus. After its confirmed a runner, all the other stuff should be tackled, issue by issue.
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Old December 30th, 2022, 12:20 PM   #85
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Quote:
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Yeah let me know it’s crazy on eBay for the pre-gens
I got out the fairing. I guess blue 250s got silver chin fairings. If you want it, you can have it for $50 delivered to CT. That's if you're not in a hurry and can wait until next time we go to town, which will be a week or two. If you want it faster we can arrange a pickup for a few bucks more. Also, I'm not in a hurry, so if you want to wait until you get it running, that's fine. I don't plan to put it on eBay or anything like that.
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Old December 30th, 2022, 02:33 PM   #86
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I got out the fairing. I guess blue 250s got silver chin fairings. If you want it, you can have it for $50 delivered to CT. That's if you're not in a hurry and can wait until next time we go to town, which will be a week or two. If you want it faster we can arrange a pickup for a few bucks more. Also, I'm not in a hurry, so if you want to wait until you get it running, that's fine. I don't plan to put it on eBay or anything like that.
Yeah thatís way better then eBay I can work with this I was looking into the parts diagrams and noticed the upper and lower attach to one another.

I was going to attempt to start the bike today but rushing around Iím short a quart of oil Iíll just pick another up tomorrow. Also I noticed when I changed the filter it had no o-ring between the filter and spring.

So tomorrow hopefully will be the day I checked and adjusted the gap on the NOS NGK plugs.
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Old December 30th, 2022, 02:35 PM   #87
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Running out of daylight and it was warm 54 F out so short sleeves today!

Looks like the headlight harness was cut and spliced
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Old December 30th, 2022, 02:46 PM   #88
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Quote:
Originally Posted by ducatiman View Post
THIS (starting/running) should be your first and primary focus. After its confirmed a runner, all the other stuff should be tackled, issue by issue.
Iím going to check the valve clearance before I start it should be pretty easy the bike has 17,101 so Iíll see how much itís out of spec.
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Old December 31st, 2022, 01:02 PM   #89
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Oh boyÖ it runs alrightÖ and I crashed.. I did a foolish mistake of grabbing a handful of front brake around 40 mph on a wet pavement I went down pretty fast.

Clutch lever bent
Clutch cable snapped
Shifter got bent
Shifter guard got bent outwards
Left foot peg bent the passenger snapped off
Somehow the motor is now out of oil (died on the fall) I suspect the o-ring didnít make a good enough seal It seemed tight enough and I didnít want to go any further.
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Old December 31st, 2022, 01:15 PM   #90
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I hope you're OK! How much riding experience do you have?
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Old December 31st, 2022, 01:22 PM   #91
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I hope you're OK! How much riding experience do you have?
I’m ok I started off with scooters I’m waiting for the msf to open back up for the season next year.
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Old December 31st, 2022, 03:03 PM   #92
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I like your style Mike! I hope you came through unscathed though. Bikes are for fixing, it'll be good.
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Old December 31st, 2022, 03:29 PM   #93
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lol yeah I skinned myself good but only needed 4 extra large bandaid's I think I can bend the shifter back but I think the switch that tells the bikes in neutral came undone.

Going to upload the first start videos and all that..

I will say I noticed a little hunting it was hard to get a consistent feel with the choke as I went to adjust the idle screw then the idle went pretty high adjusting it again had no effect. I didn't put that much fuel in the tank which may or may-not been the issue as well but then again I had no surging when riding.

Now about the oil the cover is not on tight enough? I did put the O-ring on for the cover and the bolt.
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Old December 31st, 2022, 04:14 PM   #94
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https://youtu.be/avBY4TS7y-E
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Old December 31st, 2022, 04:16 PM   #95
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Old January 1st, 2023, 12:15 PM   #96
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Old January 3rd, 2023, 01:47 AM   #97
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Can someone tell me what the stock H4 connector looks like on the bike? I found a decent priced gauge on eBay in which Iím going to swap everything over to it. The plastic is so brittle on these.

The speedometer cable broke so not that I heard anything but when it breaks nothing breaks off inside the threaded part of the gauge does it?

The clutch cable should be fun at least it can be adjusted correctly this time.
Got the fairing stay yesterday along with the headlight but a little pissed when I got the light because it wasnít the same as shown in the listing has a weird brown mark inside on the glass.

Took the fender off the replacement that came in just need to swap things over
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Old January 3rd, 2023, 05:58 AM   #98
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If you're not happy with the headlight, start a return request. Since it's substantially different from what was described, he pays the shipping. If he refuses, file a complaint, and if you have evidence to prove your point, like photos and the original description, they'll make him take it back. I've had to do that a couple times.
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Old January 3rd, 2023, 03:43 PM   #99
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Iíve opened many of headlights before so I ended up just cleaning it really good it does seem to have been opened before with all the goo at the lower clip.
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Old January 5th, 2023, 03:59 PM   #100
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Bike is ok ran it again the o-ring on the bolt wasn’t right which is why I had the oil loss.. ran it up to temp and I noticed the idle speed is very inconsistent.. I’ve gotta change these stupid grips and whatever is on the end of the throttle.

The idle speed adjustment on the carb has zero effect.. I assume it’s clockwise to increase the idle speed.

I will reach out to ducatiman

Another thing I was watching YouTube videos why is my rev limiter kicking in at 12k when I see videos of people taking it all the way to the 13k redline? I’m going to do the valve clearance tomorrow.

Left side foot bracket cracked
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Old January 6th, 2023, 05:45 AM   #101
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I went from this to this.. I used it for the housing.. the paint came off with nail polish remover.
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Old January 6th, 2023, 06:14 AM   #102
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Quote:
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Another thing I was watching YouTube videos why is my rev limiter kicking in at 12k when I see videos of people taking it all the way to the 13k redline?
It's most likely caused by tachometer inaccuracy.
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Old January 6th, 2023, 01:20 PM   #103
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It's most likely caused by tachometer inaccuracy.
Gotcha.. now Iím in need of a clutch lever since this one wonít fit

Had to go home cold and tired but I got around to adjusting the valves.. number 1 both intake and exhaust waaay out of spec so much it was out of the range of my feeler gauge set.

Second the damn exhaust adjustment (why I ended for the night) the placement of it I didnít have a good angle.

Now the air box because I was curious.. what the hellÖ itís like someone took paper towel and tore it and threw it in the air box.
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Old January 7th, 2023, 07:36 AM   #104
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If the valves are that out of spec but the engine was running, I'd step back a minute and ensure I had the engine at TDC and was checking things right.
Looks like mice made a nest in your airbox. I've seen that a lot. The wood screws are a nice touch
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Old January 7th, 2023, 07:49 AM   #105
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If the valves are that out of spec but the engine was running, I'd step back a minute and ensure I had the engine at TDC and was checking things right.
Looks like mice made a nest in your airbox. I've seen that a lot. The wood screws are a nice touch
Oh it was.. I double checked while it was hard to see the timing mark was at the 1T same with the other cylinder 2T intake was out of spec as well as the exhaust. I bet this would kinda explain why my idle would hunt while not touching the throttle. Also I had a look at the idle adjusting screw I see how it operates and why turning it had no change. It wasnít even making contact with the throttle arm.

Iíll have to post a video but it seems my throttle is sticking a bit as it has a large amount of play when it should be closed.. enough I can kill the motor if I rotate it more.
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Old January 8th, 2023, 08:38 AM   #106
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Took a day off and now to go back at it.. found my small screwdriver set because those exhaust valve adjusters was just extremely tight lol

SO I'm going to take it the throttle cables never been lubed so when I get a cable lube and the can I will check again, spark plugs will get changed today.
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Old January 8th, 2023, 01:06 PM   #107
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Well my day ended early dropped a wrench in the timing chain side.

The relay for the flashers I thought I had the right one I went based what I saw here.. nope mine has the little lock clip type plug.

So I took off the rear part of the bike to get ready to put that one since once that’s done it can be out of the way checked my connections and I’m going to swap the housing for the bike I got with the housing that came with the bike sockets in the empty rear tail lights.

Installed the Speedo cable and it works.

My bike doesn’t have the strap but I’m going to need to get one

Looks like the mess from the mouse from the previous owner found the rear.. the headlight splice is not as bad as I was expecting I just need to get a slightly bigger gauge heatsrink butt connector.

I’ve got a lot going on now

YouTube of the led turn signals

https://youtu.be/2zxN0U5lIb0

Added a video of the front turn signals

https://youtu.be/OjaXXq4qiUA

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Old January 11th, 2023, 04:56 PM   #108
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Question before I waste money on it the offset for this wrench is it good enough for the adjustments for the exhaust valves?
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Old January 13th, 2023, 03:06 PM   #109
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First time for me using these butane soldering irons tomorrow itís grabbing the tool out from the timing chain side and getting the rest of the valves in spec and soldering on the H4 connector.
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Old January 14th, 2023, 03:23 PM   #110
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Bike is running again! Used the butane soldering iron Iím so used to the electric irons but I like it! Connected the H4 crimped and heatsrinked the connections. I think Iím going to bring the front faring stay tomorrow still waiting for the hardware for it but I can at least mount some stuff without it dangling.
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Old January 17th, 2023, 10:39 AM   #111
MikeCL
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Waiting for the post office to deliver the clutch cable is a pain lol
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Old January 17th, 2023, 03:42 PM   #112
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Clutch Cable fits - EX 250 Ninja EX250 1986-2007 - Heavy Duty Clutch Cable Wire - Nylon-Lined Housing - Replacement Clutch Cable - Drive Clutch Cable https://a.co/d/37I0EN8

Looks like it’s the motion pro cable will be nice to have a working clutch again lol

Feels good just like the speedometer cable
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Old January 21st, 2023, 07:00 PM   #113
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Carb sync tomorrow finally lol
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Old January 26th, 2023, 02:42 PM   #114
MikeCL
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Thumbs up

Fuel tank is undergoing rust removal now 4 gal of water with 32 oz of rust removal liquid.
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Old February 14th, 2023, 10:02 AM   #115
MikeCL
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I just wanted to say the studs off the front flush mount signals they are M4 0.4 bolts.. for some reason home depot didn't have them in flange so I had to get the winged bolts which is not much of an issue..

I got so tired of making all the trips to find bolts that worked and no one posted info on what fit.
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