Used piston

[ovilc88]

I found a 1999 piston for my 2004. Will the piston be compatible with my engine?

[jonathan180iq]

Yep. They're all the same.
Where did you find it and how much are you paying for it? They're only like $80 @ ronayers.com

[Water Warrior 2]

I gotta side with Jonathan on this one. I would want a new piston and rings. I would feel more secure having new internal parts working for me. Not sure about the wrist pin but a good inspection wouldn't hurt.

[ovilc88]

I went ahead and purchased it for $40. It came off a motorcycle that had less than 3k on it. I figured I could give it a swing, the gentleman seemed honest about it. The condition of the piston in the pics looked very clean and doable.

[Water Warrior 2]

That's almost new. Keep us updated on your progress.

[ovilc88]

I will do

[ovilc88]

One step closer :)

[ovilc88]

Does any one know where I can buy valves for my head?? I found some on eBay that are Vesrah...never heard of. Please help!

[jonathan180iq]

You can get EVERYTHING from www.ronayers.com (http://www.ronayers.com).
Parts break down and diagrams, galore. Order by individual piece or by complete sets. It's great.

[ovilc88]

Thank you!!

[ovilc88]

Check it! :)

[ovilc88]

Out with the old in with the newish!

[isaac]

Holy crap. Did you drop a valve or four? I've heard of these motors dropping valves before. I hate to think it could happen to me, especially since my 12,000 mile engine has started sounding different in the top end lately. And I'm not exactly revving the crap out of this thing. How many miles are on your engine?

[ovilc88]

This one went off at 28,732! Not bad, I have heard of valves dropping at half the mileage I have. Its almost impossible to time it so that you can replace the valves before they go. Its all about how you drive, weather, etc...

[ovilc88]

This was the damage of one valve! Imagine what 4 would have looked like!!!
:shock:

[jonathan180iq]

That is insane...

[Water Warrior 2]

I'm amazed the other valves were not bent or damaged when that one let go. Gotta be a real strong piston not to have had the top shattered and/or even the rod bent.

[jonathan180iq]

You need to remove whatever loose filings are on there and save that thing as a paper weight

[ovilc88]

You need to remove whatever loose filings are on there and save that thing as a paper weight


O yea :D this baby is going on the wall of shame! LOL!

[ovilc88]

I'm amazed the other valves were not bent or damaged when that one let go. Gotta be a real strong piston not to have had the top shattered and/or even the rod bent.

The other valves did get hit but not as bad as the piston. As far as the rod goes I just got lucky, it could have definitely been worse!

[Water Warrior 2]

Worst case scenario: a destroyed engine. You got lucky.

[ovilc88]

I got valves I got valves (in squeaky 5yr old voice) :lol:

[jonathan180iq]

This is awesome. I love updates. you should use this like a project thread and include some how-tos and stuff while you have everything apart. It would be worth it's weight in gold.

[ovilc88]

I would love to setup the how to pics, but this is my first time doing everything so I'm learning as I go. I don't want to misinform anyone cuz I'm not 100% sure of what I'm doing. :|

[jonathan180iq]

Just take photos and then share you experience if/when you get it running.
We won't make it official if you don't want to, but I guarantee that your experience will help someone else in the future.

[Water Warrior 2]

:2tup: :2tup: :2tup: :2tup:

[ovilc88]

Alright then I will :-)

[ovilc88]

Ok gentlemen, after much anticipation I have finally come to the grand finally!!
:smile:

[ovilc88]

So now that I connected everything I have a few issues...It won't start and the neutral light isn't coming on. I don't know if those two issues are correlated or not. I check the plug and I have spark, I know I have it in neutral because the bike moves freely back and forth. My choke cable doesn't seem to work properly, It seems jammed or something?..:cry: I took it out and sprayed wd-40 in it but it didn't seem to fix it. Should I start with the cable first and rule that out?? A new cable maybe???

[blaine]

So now that I connected everything I have a few issues...It won't start and the neutral light isn't coming on. I don't know if those two issues are correlated or not. I check the plug and I have spark, I know I have it in neutral because the bike moves freely back and forth. My choke cable doesn't seem to work properly, It seems jammed or something?..:cry: I took it out and sprayed wd-40 in it but it didn't seem to fix it. Should I start with the cable first and rule that out?? A new cable maybe???
Yep.These engines are "cold hearted" & need choke to start. :) :cool:

[ovilc88]

Thanks B!

[ovilc88]

Check it out! It was snapped in half!
:D I found the booboo!

[jonathan180iq]

Hahaha. Keep the updates coming. Are you on the road now?

[ovilc88]

Not just yet, I have been away on vaca!! Lol can't wait to get her running!!

[Goose51683]

You made it to 12000, my valve broke off at under 6000miles. I'm actually doing the same thing right now.

[ovilc88]

Ok so I connected the new choke cable. I started turning her over, but no start up. I have it in neutral, clutch pulled in, choke on, side stand up, gas in it, petcock on, tried a few times and no start. I don't know why my neutral light is not coming on. I rolled the bike around to see if it was in neutral and indeed it is. I checked the bulb and it is good. I don't know if the neutral light has anything to do with the no start, but I'm just putting it out there. What do I check now???

[OldNTired]

Ok so I connected the new choke cable. I started turning her over, but no start up. I have it in neutral, clutch pulled in, choke on, side stand up, gas in it, petcock on, tried a few times and no start. I don't know why my neutral light is not coming on. I rolled the bike around to see if it was in neutral and indeed it is. I checked the bulb and it is good. I don't know if the neutral light has anything to do with the no start, but I'm just putting it out there. What do I check now???

No start, or not turning over at all?
IF it does turn over, is the petcock set to 'PRI' to get gas to the carb?
If it won't turn over, check the battery, then your fuses, then look for other causes like a short in the wiring. Check the kickstand switch also.

Then let us know what you found or didn't find.

[ovilc88]

It does turn over, so I'll start with the PRI. What does that stand for anyways? Thanks again!:grin:

[blaine]

It does turn over, so I'll start with the PRI. What does that stand for anyways? Thanks again!:grin:
Pri stands for prime.In that position fuel flows without the engine running to fill the carb bowls with fuel when the bike has been sitting for long periods or the carbs have been drained.
:) :cool:

[jonathan180iq]

PRI would have been my first guess too, since this is essentially the first time crank on your new engine. It's like a rebirth. You should call this thing the Phoenix. :)

After that, if you don't start smelling gas after a few cranks, take a dollar bill and lay it over the exhaust end. You want to see if blowing out with each puff of the engine. If not, then there is likely a compression issue. (I wouldn't worry about that yet though. But it would be good to know for mental peace, since you just put this back together from scratch.)

There are a couple of known issues with starting so it doesn't automatically mean that there is a major issue. Keep us updated.

[ovilc88]

Ok so, I set the fuel valve on PRI and cranked it, but no luck. Fuses were all 100%. Dollar bills flying out of exhaust side. I disconnected carbs and fuel was in the bowls. On a side note (Would it be ok if I started the bike with no carbs on and sprayed carb fuel/cleaner in the intake side??) I was looking at the pilot jet and the needle broke off into the carb body, also I, not knowingly; drilled what I thought was the copper cover for another screw and it turned out to be the copper cover for some fuel inlets! :? Yea, so now I have to purchase a pilot jet and the little copper cover...

[ovilc88]

Copper cover, I searched the fiche at ronayers, but I'm not 100% if the Carburetor has this item in the pic. I saw something that might be it, but it looks like another screw. It has description
M/J 52.5 (N1022 Anybody have an idea if that's it?

[ovilc88]

Pilot jet, needle head broke into carb body

[jonathan180iq]

Copper cover, I searched the fiche at ronayers, but I'm not 100% if the Carburetor has this item in the pic. I saw something that might be it, but it looks like another screw. It has description
M/J 52.5 (N1022 Anybody have an idea if that's it?

This first one is a jet.

This is what the main jet looks like:
http://www.scootersoriginali.com/osc/images/Dell-1486_600x600.jpg
(Ronayers microfiche # 16 under carburetor)

Given the small number indicated on the side of the one in question, it's obviously not the main but it's also not one that I have pulled from the bike before.
(EDIT: This is part # 29 on the microfiche - "Pilot Jet main")

[jonathan180iq]

PS: Is the photo you have of that jet hollowed out on the top? Is that where your drill hit it or was it already like that? Those inlet hole sizes are very precise and need to stay that way. Order a new one.

[ovilc88]

It was already like that, the jet holes are unmolested. The copper cap that covers those holes is what I need. On the other hand, would it be ok to pick up a used one on eBay for around $110??

[mrgz250]

when it comes to parts for the gz 250 engine dont short change yourself by using used parts that are internal its just not a good thing to do it sounds good in the beginning but in the long run I myself
dependability could be lost thats the way I think do it right the first time or dont do it at all I love my gz she is tight

[Goose51683]

I would say don't buy a brand new part unless you have to. I can't stand it when people think they have to buy brand new when a used part is if great shape.

Look at the actual part. If it looks like the new part and doesn't have any actual damage then buy it for half the price and get back on the road.

I will say that the extra 10 mins to do a thorough inspection of whatever your thinking about buying used is worth it's a million bucks, but don't assume that because its used its inferior. If we all thought that 95% of us wouldn't own the bikes we have.

[ovilc88]

Well spoken Goose!!! Thank you.

[Goose51683]

Thanks I try. You'd think it was common sense but apparently it's not as common as I'd hoped

[raul10141964]

you can repair your plug using something like this

http://s12.postimg.org/e8ucnilg9/JB_Weld_8267_S_rw_209906_319159.jpg (http://postimg.org/image/e8ucnilg9/)

[ovilc88]

I can get that and put the plug in its place then fill in the hole I drilled. I can also use the JB KWIK WELD.

[ovilc88]

Finally got'er running today!!!! Woooohoooo!!!! It felt so good feeling and hearing that baby rumble!! I installed a new pilot jet needle, washer, o ring and spring. I got the hole I wasn't suppose to make filled with JB-Weld! Started up on the first crank :grin: I rode her around the neighborhood and it felt like freedom! Just gotta finish putting the exhaust on, little adjustment on the carb replace the little window on the master cylinder, bleed brakes, clean and polish :) oh and did I mention I'm SUPER EXCITED!!!!! I want to thank everyone who had a hand in the advice, tips, and encouragement I received from this beautiful forum full of awesome peeps! God Bless!

[Water Warrior 2]

:2tup: :2tup: :2tup: :2tup: :2tup: :2tup: :2tup:

[Goose51683]

Awesome to hear a success story on here!

[blaine]

Awesome.Congrats!!!! ;) :)

[jonathan180iq]

http://img.pandawhale.com/29690-super-happy-dude-gif-veiI.gif
hmmm....HMMM????......YYYAAAAAAAYYYY!!!!

[ovilc88]

I finally fixed the master cylinder sight glass. Check it....

[ovilc88]

I finish bleeding the brakes and notice that the brake pads are down to metal :/ o well. One more new thing for the bike. I wonder if I can get the rotor cut? Anybody know?

[jonathan180iq]

You mean like machined? I don't see why not. You'll just need to check the service manual for the minimum thickness and make sure your machinist doesn't exceed that.

[ovilc88]

Awesome, thank you!

[5th_bike]

1 - Congratulations on getting it running, YAY !!!! :rawk:

2 - Probably superfluous, but when you change brake pads, dont forget to transfer the two shims to the new brake pads.

[JohnC]

Not much material to cut on the rotor. If it's not that bad just go with it. The limit is .180"

[ovilc88]

Re-use shims, Check. Thanks

[ovilc88]

Rotor is not bad I can def use it the way it is

[jonathan180iq]

Unless you've got some bad pitting or maybe a cut mark from the bad pad, I would just use brake cleaner and slap it on there.

[ovilc88]

I thought the new cap for my sight glass on the master cylinder would hold, but the fluid ate right through in less than a week!! :( O well, I found a master cylinder with brake lever on eBay for $20. I'll just install that and call it a day. I have to look for a glass piece that can fit the hole of the master cylinder to fix the original one and then sell it! 8-)

[jonathan180iq]

I did the same repair one time with this stuff called QuickSteel and I used a dime to cap the hole. It lasted 2 years and so far the new owner hasn't complained about it either. I guess I should have said that a few posts ago...

[JohnC]

I have to look for a glass piece that can fit the hole of the master cylinder to fix the original one and then sell it! 8-)

Google "watch crystals". They come in all sorts of diameters and thicknesses. That's what most folks use (those that don't use dimes!).

[ovilc88]

Thank you!!! lol

[Goose51683]

Hilarious that literal money is cheaper than the part it would take to fix this.

[jonathan180iq]

Thomas Jefferson was too fat and the Penny just didn't have the same luster as the shiny head of FDR.

[Goose51683]

I prefer Benjamin but e dissolves so quickly!