Project 300 "this is not sparta"

[razor02097]

Just wanted to update after the carb cleaning...I replaced the spark plugs because the retard at the parts place gave me one DR9EA and one D9EA when I asked for D8EA. I guess I was stupid for not checking them before installing them... I replaced both plugs with D8EA and gaped them at what the manual said.

It runs like a different bike! I can chug along in first and scream in 5th. Now this bike actually RUNS like it only has 4000 miles on it. I also adjusted the speedometer needle about 10 times until I got it relatively close to accurate. The average MPG is down to about 50 because I can't keep off the throttle...

I wish it would quit raining... it has been nice here and can only ride one or two days a week because it rains the rest of the time

 

[Guest]

Good news! My fuel economy has gone to crap lately too... possibly for the same reason

 

[razor02097]

Gentleman.... remember to always check your nuts. And remember the cotter pin

Luckily the brake cam and rod are still available. The arm wasn't so I replaced it with one from a 1984 gs250. It fits and works like a charm.

 

[Guest]

Gentleman.... remember to always check your nuts. And remember the cotter pin

Luckily the brake cam and rod are still available. The arm wasn't so I replaced it with one from a 1984 gs250. It fits and works like a charm.

Oooops! And I'm very glad you included a pic with the comment "remember to always check your nuts"... hahaha

I assume you were able to deal with the situation in a non-damaging manner given that you're able to share the pic's? Can I ask what the effect was?

 

[hjacobmiller]

Hi,

I'm restoring the same bike! Have you encountered a small drain hole in the bottom of the starter well (underneath the starter)? I didn't know if there was a plug that goes there or if it just is open.

Looks great! I'll share some pictures of mine as it comes a long too!

 

[Guest]

I could be wrong, but I would think that little drain hole allows any fluids that collect to drain from there. Should you plug it and wash your bike then try to start it, you may smoke your starter from the water that collects .

 

[hjacobmiller]

That is what I thought, but I wanted to double check!

 

[razor02097]

Oooops! And I'm very glad you included a pic with the comment "remember to always check your nuts"... hahaha

I assume you were able to deal with the situation in a non-damaging manner given that you're able to share the pic's? Can I ask what the effect was?

Well the brake strut bolt came off due to a missing D.A. pin. D.A. stands for dumb ass... as in I was a dumb ass for forgetting the pin... heh... this happened when coming to a stop the rear brake was applied and since the strut became detached the drum assembly rotated with the wheel bending the rod in a u shape which applied the brake more until the arm bent and the brake cam snapped... that is some thick metal too...

The only damage to 300 is some marks on the spokes where the bolt rubbed against them. I was able to use the OEM tool kit I had ordered to disable the rear brake and limp home. Glad I got that tool kit :lol:

All is well though I have replaced all the parts shown in the picture and I'm back riding again. Total cost of repair was under $50

 

[BigRock]

DA club

DA club

I'm here to join the dumb ass club. I came across your photos and thought they were mine. Same thing with the same resutlz happened to me 2 days ago. I'm checking my nuts and bolts more offten now!:lol:

 

[Guest]

Well the brake strut bolt came off due to a missing D.A. pin. D.A. stands for dumb ass... as in I was a dumb ass for forgetting the pin... heh... this happened when coming to a stop the rear brake was applied and since the strut became detached the drum assembly rotated with the wheel bending the rod in a u shape which applied the brake more until the arm bent and the brake cam snapped... that is some thick metal too...

The only damage to 300 is some marks on the spokes where the bolt rubbed against them. I was able to use the OEM tool kit I had ordered to disable the rear brake and limp home. Glad I got that tool kit :lol:

All is well though I have replaced all the parts shown in the picture and I'm back riding again. Total cost of repair was under $50

Aaah I see! I couldn't understand how it bent the rod, but now I see... bugger! Glad it all ended up well and not in disaster though.

I'm going to have to check the pin and bolt before I leave for work in the morning now

 

[razor02097]

I'm here to join the dumb ass club. I came across your photos and thought they were mine. Same thing with the same resutlz happened to me 2 days ago. I'm checking my nuts and bolts more offten now!:lol:

Glad I'm not the only one that did this. I am hoping it will serve warning to others

 

[JEEPRUSTY]

Oooops! And I'm very glad you included a pic with the comment "remember to always check your nuts"... hahaha

I assume you were able to deal with the situation in a non-damaging manner given that you're able to share the pic's? Can I ask what the effect was?

THIS could have been one hell of a lot worse.
It happened ot me once and it bent the lever into a nice curve
locked the rear brake and near killed me.

I think if you check the fiche for that lever you will see it is unavaliable.

 

[razor02097]

The brake arm is indeed unavailable but one from a 1984 gs250 is available and does work.

 

[hjacobmiller]

Just had a couple quick questions about your restoring project. Looks great!!

Did you run into these on the carbs?

And also, did you find a carb rebuild kit for it? I haven't been able to find one but I would like to rebuild mine. I've cleaned them pretty well but I think there may be some parts that could be replaced. I didn't know if there was a compatible kit or if you found anything.

Are there any tricks you'd like to share about the getting the needle jet out?

I'll send you a link to my thread if you're interested. Great to see another GS300!!

 

[GateKeeper]

What type of kit are you looking for ?

did you check out here ?

http://www.cycleorings.com/

or is there more that you need ?

.

 

[hjacobmiller]

I was hoping to get a complete rebuild kit with jets and things like that. I thought that someone might know of kits that come with washers, jets, etc.

 

[Guest]

I was hoping to get a complete rebuild kit with jets and things like that. I thought that someone might know of kits that come with washers, jets, etc.

Typically the kits are junk... you should find the float bowl gaskets still available from Suzuki, cycleorings.com may have suitable O rings, and unless there's something wrong with your jets then they just need a good soak in carb dip with the carbs...

 

[razor02097]

I was hoping to get a complete rebuild kit with jets and things like that. I thought that someone might know of kits that come with washers, jets, etc.

I did not replace any parts in the carbs. I cleaned them out as best I could. I think a monkey devices the carbs last time because the adjustment screws were out 3 turns.... I reassembled everything and set the adjustment screws to 1.5 turns out. Most of the time unless you tear a gasket or the gaskets are just in bad shape there isn't really a need to replace everything. It is just throwing money at a problem that might not be the solution.

The plugs in the carbs is a good sign it means they are still factory set. Use a drill bit to get them out. They are aluminum so don't press and use a slow speed. They should pop right out. The adjustment screw is under the plug.

 

[hjacobmiller]

How did you get the needle jet to come out? I couldn't get it to budge..

 

[razor02097]

Make sure you have a screwdriver that fits correctly and spray it with penetrating oil. Take your time.... breaking a parts in the Carb would be a disaster.