Project GPX - A return to biking after a 12 year break

[Stonefly]

Hi All,
I decided after a somewhat protracted break of 12 years to get back on a bike.
I had stopped riding in 1999 as a result of being a motorcycle courier for the previous miserable 8 years and the job just totally killed my enjoyment of riding bikes.
However, i eventually started to think about bikes again a couple of years ago and really started missing riding around in our glorious sunny summers!
I had limited funds for this, but a work colleague told me she had a bike in her garage that i might be interested in.
I went to see the bike and it was a Kawasaki GPX 250R F9.
She had bought it new in 1998 and hardly ever used it.
When i saw it, it had not been started since 2006 so i knew it would need a bit of work doing, but it was cheap.
Incredibly, it had only covered 538 miles from new - it was not even run in yet!
The bike is actually in very good condition with very little corrosion anywhere.
Basically, it needed a really good clean and polish and some general fettling to get it started.
So, having done the deal (I am too ashamed to tell you how little i paid for it) i brought it home and stood back with a camera.
I took a few pics and then over the next few days set about giving it a good clean and polish
Its looking very nice but i now have the task of trying to get it started.
So far, i have asserted that the battery is totally goosed (no surprises there then) and that there is liquid fuel in the tank that still smells like petrol.
I have managed to extricate the spark plugs and added a little oil to the cylinders. That should help it lube the rings before i try and spin the motor.
This week, i shall purchase a battery and put in fresh fuel and hopefully will have it running.
I will post some pics as i work on it if i can work out how to insert pics but so far, i have had little success with this.
if anyone could advise me on inserting pics please?
I shall attempt to insert one now, but if it does not work, i shall try and include them in the next post if i have worked out how to do it.
https://www.flickr.com/photos/23536241@N04/5948083938/
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Current......Kawasaki ZZR1200 C2H and Kawasaki ZZR600 E7
Previous....Yamaha FS1E, Honda SS50, Suzuki AP50, BSA Bantam D14, Honda CD175, Honda CB250N, Kawasaki Z250A3, Yamaha RD250E, Kawasaki Z400, Kawasaki Z500, Kawasaki GPz550, Honda NTV600, Kawasaki GT750, Kawasaki Z1000R, Kawasaki GPX250

[hazza]

Hi mate,

upload you photos to photobucket, thenp aste the IMG codes in here. simple!

As for the bike, its a nice sensible choice to get you back into things. I have an eliminator 250 which i use for commuting to work, which isnt as slow as i thought it would be. It shares the same engine as the GPX 250 although yours has a more aggressive cam so it makes a little more power. When i had mine, it had been in a field uncovered for two years and not started. First job was to drain the tank and the float bowls on the carbs. I then removed the carbs and gave them a good clean. Removed the spark plugs and it was apparent that they had been changed very recently, as the previous owner indicated. I then filled it up with petrol, along with a new battery and an oil change and tried to fire her up. Just put the choke on full and crank it over, dont be tempted to use the throttle, ive found on mine it certainly dosent like it. Thats all it took to get mine going. After a short I soon discovered that my cooling system wasnt functioning. I put it back in the garage, drained the coolant, re filled and most importantly bled the system. Thats all ive had to do to mine since owning it, its been great (touch wood). If you are unsure about anything ive explained to do, and even if you arent, this is a great resource!



https://faq.ninja250.org/wiki/Main_Page


Hope this helps,

Harry.
____________________
3 Honda NC50's(Sold)-->'72 Puch Maxi S (Sold, want it back!)--> '90 Yamaha RXS 100 (Stolen)--> '87 Honda Cub 90(Sold) --> '95 Kawasaki Eliminator (Sold) --> '98 Bandit 600 (Sold) -->'07 SV650S (Current)

[mibman2003]

The GPX's are nice bikes, I own a 1986 GPZ400r.But let me tell you one thing, be prepared for continual problems with the carburettor's on these bikes...!
They are a proper pain in the arse to sort - trust me, been there done that!
But apart from that, it's a cool bike, get some pic's up!
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Does anybody speaka engrish?

[Stonefly]

Hazza, Thanks for the image tip, its very much appreciated. Also thanks for the advice and the link. It looks like it will be pretty useful.

mibman2003, thanks for that tip - when I was 17, I had a Z250A and the carbs were exactly the same!! it was never easy to get them in sync and cold starting was never my idea of fun. It would seem that progress has bypassed the kawasaki carburettor engineers?

As you will see, the bike is in pretty good condition, having been dry-stored in a garage. I have had the plugs out and they are pretty much brand new. It had been serviced before being taken off the road. It had covered about 15 miles after the service and I am tempted to start it with the oil that is in - it is obvious from looking at the oil level window that the oil is clean and fresh (the service bill states it was filled with silkolene semi-synthetic 10/40.

The current bad weather is hampering things at the moment but hopefully it will improve later this week and allow me to get some more work done.

Ok, here are some pics so far.........

https://img.photobucket.com/albums/v448/stonefly/Project%20GPX/DSCF4157a.jpg
This is the bike as it arrived at my house.
The pic makes it look pretty clean but it was in fact filthy with dust and grime.

https://img.photobucket.com/albums/v448/stonefly/Project%20GPX/DSCF4158a.jpg
It is a little clearer here, that there is a layer of crud covering the tank and the rest of the bike.

https://img.photobucket.com/albums/v448/stonefly/Project%20GPX/DSCF4162a.jpg
As i said, the mileage is unbelievably low and i know that it is genuine. (I have known the previous owner as a colleague and friend since 2003)

https://img.photobucket.com/albums/v448/stonefly/Project%20GPX/DSCF4165a.jpg
After a good wash and the application of some autoglym super resin polish, its looking very shiny indeed.
The four screws that secure the fairing to the tank are missing but i have ordered a set this very evening from Z-Power in Leigh.
They should be arriving on Wednesday

https://img.photobucket.com/albums/v448/stonefly/Project%20GPX/DSCF4167a.jpg
The paintwork is in very good condition and now that it has been treated to a good polish, you could almost use it as a shaving mirror!

Well thats it for photos just now. I need to concentrate on getting the bike started this week although I have other things going on which may hamper progress.
The main tasks this week will be to purchase a new battery, to flush the tank and carbs, add fresh fuel, and hopefully spin the motor with the plugs removed.
If all that goes without a hitch, I shall then attempt to start it.
____________________
Current......Kawasaki ZZR1200 C2H and Kawasaki ZZR600 E7
Previous....Yamaha FS1E, Honda SS50, Suzuki AP50, BSA Bantam D14, Honda CD175, Honda CB250N, Kawasaki Z250A3, Yamaha RD250E, Kawasaki Z400, Kawasaki Z500, Kawasaki GPz550, Honda NTV600, Kawasaki GT750, Kawasaki Z1000R, Kawasaki GPX250

[hazza]

wow! that looks like a minter! On the paintwork front any small scratches ( i thought i could see a few long ones on the tank) can be easily removed with a dual action polisher and a bit of patience.
____________________
3 Honda NC50's(Sold)-->'72 Puch Maxi S (Sold, want it back!)--> '90 Yamaha RXS 100 (Stolen)--> '87 Honda Cub 90(Sold) --> '95 Kawasaki Eliminator (Sold) --> '98 Bandit 600 (Sold) -->'07 SV650S (Current)

[Stonefly]

Hazza, yes there are a couple of long scratches on the tank. It had been stored in a garage for 5 years and 'things' including a mountain bike, had been stored on and around it. Bit of a shame that, but I will definitely try a dual action polisher. Can you recommend one to me please?
____________________
Current......Kawasaki ZZR1200 C2H and Kawasaki ZZR600 E7
Previous....Yamaha FS1E, Honda SS50, Suzuki AP50, BSA Bantam D14, Honda CD175, Honda CB250N, Kawasaki Z250A3, Yamaha RD250E, Kawasaki Z400, Kawasaki Z500, Kawasaki GPz550, Honda NTV600, Kawasaki GT750, Kawasaki Z1000R, Kawasaki GPX250

[hazza]

Depends what you want really. I had mine for the car, its a kestrel das-6 pro and cost me £150 with all the pads and compounds. You can get silverline rotary polishers off ebay for around £40 quid which work great in experienced/careful hands but you can burn through the paint! Dont be tempted to get a halfords jobby with a fake lambswool pad. It will be useless. I know most hire shops will hire pro polishers out for around £30 quid. The results are fantastic if you do the whole bike though. Just start with the lease aggressive pad/polish combination first and if after a few passes that dosent work, move up.

Basically if you will find use for it afterwards (ive done about 5 cars and two bikes with mine, including using an old pad and auto sol to polish my alloy-----> https://www.bikechatforums.com/viewtopic.php?t=222429 )
then go for a proper kit, www.cleanyourcar.co.uk do some fantastic stuff, if its a one use thing/strapped for cash then get a silverline ( https://cgi.ebay.co.uk/7-pc-silverline-polishing-kit-polish-buffing-buffer-car-/230648541978?pt=UK_Home_Garden_PowerTools_SM&hash=item35b3b9731a#ht_1199wt_907 ) or a rental.

Hope this helps

Harry
____________________
3 Honda NC50's(Sold)-->'72 Puch Maxi S (Sold, want it back!)--> '90 Yamaha RXS 100 (Stolen)--> '87 Honda Cub 90(Sold) --> '95 Kawasaki Eliminator (Sold) --> '98 Bandit 600 (Sold) -->'07 SV650S (Current)

[Stonefly]

Right, well I got her running on Friday morning after fitting a new battery and putting fresh fuel in the tank.
Once the smoke had cleared (I put some oil down the plugholes last week to lube the rings) and the motor had warmed up, she was ticking over very sweetly.
I booked an MOT for Saturday morning and just after 8.30am, I had a pass certificate in my grubby mitts.

HOWEVER........... I noticed on the journey there and back (a 22 mile round trip) that she would not rev beyond 5K RPM.
I suspect gunge in the main/needle jet, or possibly the slides sticking and not lifting the needle.
I suppose its possible that the diaphragms are holed, but fingers crossed its not that.
Any ideas/suggestions?
Removing the carbs is going to be an absolute nightmare of a job, though cleaning will be easy enough. Is there anything I can use to flush them through without damaging the diaphragms?
I was hoping to get her taxed on Monday and start using her for commuting, but its a long commute when she will only manage 40MPH!!!
____________________
Current......Kawasaki ZZR1200 C2H and Kawasaki ZZR600 E7
Previous....Yamaha FS1E, Honda SS50, Suzuki AP50, BSA Bantam D14, Honda CD175, Honda CB250N, Kawasaki Z250A3, Yamaha RD250E, Kawasaki Z400, Kawasaki Z500, Kawasaki GPz550, Honda NTV600, Kawasaki GT750, Kawasaki Z1000R, Kawasaki GPX250

[pepperami]

First things first, you dont need that bike so give it to me , secondly I recon you`ll have to bite the bullet and strip those carbs.
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I am the sum total of my own existence, what went before makes me who I am now!

[blurredman]

I like the GPX, always wanted one. I prefer the look of the 400 and 600 though.

But cool bike if you're coming back into biking again I suppose
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CBT: 12/06/10, Theory: 22/09/10, Module 1: 09/11/10, Module 2: 19/01/11
Past: 1991 Honda CG125BR-J, 1992 (1980) Honda XL125S, 1996 Kawasaki GPZ500S, 1979 MZ TS150.
Current: 1973 MZ ES250/2 - 18k, 1979 Suzuki TS185ER - 10k, 1981 Honda CX500B - 91k, 1987 MZ ETZ250 (295cc) - 40k, 1989 MZ ETZ251 - 50k.

[LongJohn22]

No doubt about it, that's a smashing find. Something to ponder, with such a low mileage, those are most likely the original tyres, and after 13 years are probably well'ard by now,not much 'sticky' left, just a thought.

[Stonefly]

I started pulling the carbs off last night but ground to a halt!!
I managed to remove them from the intake stubs and air box rubbers, but got no further when I realised they are attached to the cooling system. I decided to try and work on them as they were - just kinda hanging there.

I managed to remove the CV tops from the diaphragms, and took them out for inspection. I was overjoyed to find them both intact.
However, I was not able to remove all the screws holding the float bowls in place and had to give up at that point. I didnt want to risk rounding the cheap crap screwheads.
I am now convinced that the main and/or needle jet is gunged up.
Its the most likely problem since it was stood for 5 years and bowls had not been drained.
Its such a shame as the motor is really sweet and smooth up to 5000rpm.

I put it all back together and it started first prod of the starter button.
So, I have now booked it into a local workshop to have them clean the carbs for me. It will probably cost a bit, but considering the bike has cost me less than £100 so far, I guess I cant complain too much.
____________________
Current......Kawasaki ZZR1200 C2H and Kawasaki ZZR600 E7
Previous....Yamaha FS1E, Honda SS50, Suzuki AP50, BSA Bantam D14, Honda CD175, Honda CB250N, Kawasaki Z250A3, Yamaha RD250E, Kawasaki Z400, Kawasaki Z500, Kawasaki GPz550, Honda NTV600, Kawasaki GT750, Kawasaki Z1000R, Kawasaki GPX250

[stevo as b4]

It looks a real minter, what a find! It's practically a new bike which is the good bit!

The bad bit is that it's far too nice and totally original to modify or make a project out of. It would even be a shame to use that as a daily runaround, so if it were me id have to sell it or swap it for a scabby one and a few £££ notes as well.

[Stonefly]

Wet weather and family coming to visit have hampered any progress this weekend. I have acquired a set of good quality screwdriver bits to try again at removing the carb bowls. Hopefully, next week I will have sorted the carburation issues, saving the cost of a garage doing the job, and have a fully functional machine.

On the plus side, it was nice on Wednesday so I rode it to the post office, taxed it, and went out for a ride in the rush hour traffic - just to get used to riding in traffic again basically, plus the traffic moves so slowly at that time, nobody notices it will only do 40mph!!!
____________________
Current......Kawasaki ZZR1200 C2H and Kawasaki ZZR600 E7
Previous....Yamaha FS1E, Honda SS50, Suzuki AP50, BSA Bantam D14, Honda CD175, Honda CB250N, Kawasaki Z250A3, Yamaha RD250E, Kawasaki Z400, Kawasaki Z500, Kawasaki GPz550, Honda NTV600, Kawasaki GT750, Kawasaki Z1000R, Kawasaki GPX250

[Stonefly]

Well, despite the generally miserable weather, Tuesday evening was dry and fairly bright so I decided to tackle the carb issue.
What the manual does not show, is that there is a pipe running from the cooling system to the carbs, presumably to prevent carb icing. I didnt realise this was a problem on the little GPX but its there anyway.
So with a decent set of driver bits, I set about removing the carbs fully from the bike.
It turned out to be actually quite an easy job, despite my misgivings, and I soon had them on the workbench ready for a strip down.
The monkey metal screws holding the float bowls in place had been the problem that beat me last time, when the carbs were still attached to the bike by various cables, but now they were on the bench, I was able to apply a good deal more pressure to the screwheads and they eventually cracked free.
Inside the bowls was not nearly as bad as I had imagined.
Sure, there was a bit of old fuel gunge at the bottom of the float bowls, but not as much as I had expected.
It was at this point that I realised I had forgotten to buy carb cleaner - a quick trip to Halfrauds sorted that out.
The pilot, main and needle jets came out easily and were free of gunge and all the holes were clear. This bothered me, since the bike was running like they were blocked.
Anyway, I continued to soak the carbs in carb cleaner and wiping off any signs of muck.
It was at this point that I noticed something scrape the tip of my finger just in front of the butterfly valves on the engine side.
It was the tip of the mixture screws sticking up from the mixture port!
Well it was a no brainer..........I tightened the mixture screws until they just touched home - one and a quarter turns!!!
The previous owner had taken the bike to a local dealer to have it serviced as it had been stood a while and they stripped and cleaned the carbs. Presumably, they got the trainee to clean the carbs as the concept of '2.5 turns out' was clearly lost on him (or her)
Anyway, I turned the mixture screws out a FULL 2.5 turns and reassembled the carbs.
After much effing and jeffing, and a fair amount of skin removed from my hands, the carbs were back on the bike.
Now I was feeling a little nervy, but turned on the ignition and hit the starter.
It spun over for what seemed like an eternity, but eventually the fuel filled the bowls and she sparked into life.
The motor sounded smoother and sweeter than before, so I grabbed my lid and jacket and hit the road.
I was amazed!!!
The problem of not revving beyond 5K RPM had gone and the bike was more than eager to accelerate quickly.
So, after a good 40 mins riding around, I headed home. I was more than pleased at having solved the mystery and saving myself over £150 for a garage to clean the carbs for me.
Best of all though, I now have a fully functional bike to get me back on the road again after 12 years.

Can I just say a BIG thank you to Hazza, who directed me to the Ninja 250 riders club website- it is a great resource and was invaluable in getting the bike back on the road after it had been stood in a garage for 5 years - Cheers Hazza, much appreciated!

Finally, the total cost of the bike and getting it back on the road?

Bike £60
New Battery £26
4 new fairing screws £10
Can of carb cleaner £6
Total - £102!!!

........and that, my friends, is what I call a RESULT!!!
____________________
Current......Kawasaki ZZR1200 C2H and Kawasaki ZZR600 E7
Previous....Yamaha FS1E, Honda SS50, Suzuki AP50, BSA Bantam D14, Honda CD175, Honda CB250N, Kawasaki Z250A3, Yamaha RD250E, Kawasaki Z400, Kawasaki Z500, Kawasaki GPz550, Honda NTV600, Kawasaki GT750, Kawasaki Z1000R, Kawasaki GPX250

[serlant]

you paid 60 fucking pounds?!?!? you lucky bastard! someone on their a2 would probably pay 10x that for it when you're finished with it, good find!
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04 CBR1000RR, 1995 Husqvarna TE410, 1998 VTR1000(Sold), 1990 XJ600(sold), 1996 KH125(dead and sold)

[Stonefly]

[cb1rocket]

£60!!!!!!??????!!!!!

You bought a minter for that much, my rust bucket cost more than that when i spent £60 on it plus a further 400.



........lucky sod (bastard!)