Excellent :)

Those air boxes are a PITA.. I found that I could pull the carbs out
before the air box with quite a bit of force, but it is hard :) Someone
else might have some tips for this.. ?

While you're doing the carbs, make sure you check the rubber diaphram's
for the slides carefully for any holes or tears - you can use a torch
behind them and look through them for any light.. You might also find
this site worth the look:

http://au.geocities.com/ozcross250/

Specifically:

http://au.geocities.com/ozcross250/holder.html and;
http://au.geocities.com/ozcross250/needles.html

As for paint, you could go to any hardware store (Bunnings) and you
should be able to get some high-heat paint that's used on engine's.. I
think they call it engine paint, comes in a spray pack and in quite a
few colours.. Ask the sales person about any prep-work you might have
to do before spraying (undercoat/sanding/prepsol etc).

As for the muffler, I think there'd be a few options there. You could:
a) Go get some stock mufflers that aren't rusted (good luck!)
b) Get some mufflers from a similar Suzuki (they might fit!) from a
wreckers
c) Get the exhaust modified to a 4-into-1, and grab an after-market can
from the wreckers/new or one from another 250..
c2) You MIGHT find that the Across headers fit, they're already a
4-into-1, and you could just get a pipe/can custom fit on the end.

If you're still looking for an Across manual, try here:

http://autos.groups.yahoo.com/group/SuzukiAcross/files/


Let us know how you go! :)


Cheers,


Carl

On Tue, 2005-07-12 at 10:31 +0000, casper05james wrote:
> Thanks, The carb cleaner worked so well it stripped the paint clean
> of the carbs!!!
>
> It took me almost 2 HRS to get the air filter box out???
> Not sure how you are supposed to get those darn things out!
>
> All blockages have been cleaned out except for one seized piston in
> the carb, so I'll have to pull the darn thing apart! Luckily you guys
> were here to give me the PDF on how the carbs pull apart!
>
> Does anyone know the paint they use on the carbs/engine/headers???
>
> I am pretty sure that anything i try will just burn from the heat...
> Any suggestions???
>
> Any suggestions on cheap mufflers... preferably the quite kind???
>
> Thanks Heaps,
>
> ROB
>
> --- In suzuki250fours@..., Carl Johnston
> <cjohnston@b...> wrote:
> > The Across has (what I believe to be) a later version of what's in
> the
> > GS250FW, the manual won't help you with specifics (valve clearances
> > etc), but it will help with engine and carbs. It's better
> illustrated
> > and quite useful when used with the GS250FW manual. I've also
> browsed
> > the Across forums in search of some troubleshooting advice, which
> > carries over quite well.
> >
> > Carb cleaner you'll get from any auto parts store (SuperCheap,
> Autobahn,
> > Burson's etc) and usually runs at about $8 for a spray can.
> >
> > Cheers,
> >
> >
> > Carl
> >
> > On Sat, 2005-07-09 at 01:21 +0000, casper05james wrote:
> > > Thankyou Carl,
> > >
> > > I downloaded the PDF's They were helpful!
> > > Do you know if the Across has alot in commen or just the carbs?
> > > Also where would I find this carb cleaner it sounds like it might
> > > save my skin?
> > >
> > > --- In suzuki250fours@..., Carl Johnston
> > > <cjohnston@b...> wrote:
> > > > Assuming that you'll be doing this yourself, I'd recommend you
> > > download
> > > > the workshop manual from this site - then go and look for a
> GSX250F
> > > > (Across) manual as the carbs are very similar (and the diagrams
> in
> > > this
> > > > manual are a lot better).
> > > >
> > > > Pulling them out of the bike is more difficult than cleaning
> them -
> > > it's
> > > > a rather tight squeeze in there.
> > > >
> > > > Once you've got them out, just pull them down (one at a time)
> and
> > > > methodically store all the pieces in separate trays, cleaning
> them
> > > as
> > > > you go - just make a mental note (or a digital camera comes in
> > > handy) of
> > > > where everything goes, and how it goes together.
> > > >
> > > > There are three adjustments on these carbs - Syncing the
> throttle
> > > > between them, needle positions, and air jet positions. You
> > > shouldn't
> > > > need to touch the carb sync screw (though I recommend syncing
> them
> > > > afterward) or mess with the needle positions. As for the air
> jets,
> > > just
> > > > count the number of turns it takes to screw each of them in
> > > (softly!),
> > > > and set them back to that when you're done.
> > > >
> > > > The rest of the cleaning is just a matter of either soaking the
> > > parts in
> > > > carb-cleaner, or spraying the passages with carb-cleaner.
> > > Everything
> > > > should be blown dry with compressed air..
> > > >
> > > >
> > > > Either that, or you could just take them to a shop to do :)
> > > >
> > > >
> > > > Did you end up getting exhaust pipes for your bike?
> > > >
> > > >
> > > >
> > > > On Wed, 2005-07-06 at 09:01 +0000, casper05james wrote:
> > > > > Got it for $300.
> > > > > Needs carbs rebuilt due to fuel blokage.
> > > > >
> > > > > The bike is near new, black in colour and only 20,000km.
> > > > > Garaged since 1993.
> > > > >
> > > > > Another $500 and i'll have it registered.
> > > > > On the road for meisly $800!
> > > > > And I'll be able to sell it for $1500 easy- quoted $1999
> > > > >
> > > > > Does anyone know a good way to clean out a fuel blockage?
> > > > >
> > > > >
> > > > >
> > > > >
> > > > >
> > > > > Yahoo! Groups Links
> > > > >
> > > > >
> > > > >
> > > > >
> > > > >
> > > > >
> > >
> > >
> > >
> > >
> > >
> > > Yahoo! Groups Links
> > >
> > >
> > >
> > >
> > >
> > >
>
>
>
>
>
> Yahoo! Groups Links
>
>
>
>
>
>