250s start again

After a battle with fouling plugs, I have the Katana 250 and ZZR250 going

Seat covers for both bikes are done, and both are ok except for small rips in the top left corner of each. These pre-cut seat covers leave nothing on the corners and just enough to grab on the sides. I’ll remember this for the next covers I have to do.

Katana 250

  • Finally found a water union on Jauce to replace the once that had corroded and repaired. Part no 17857-45D00 is the same as for the GSX400.
  • Got the seat back on and went to try and ride it. Forgot that the rear axle wasn’t tightended up and the loose chain ended up cracking the procket cover. Dang. Something that’s straightforward to fix.
  • Bled the rear brake.
  • Got it started and took it for a spin round the yard.
Ryan on a test ride


  • Started and would only idle (even with full throttle)
  • Left the throttle open (tying a piece of rag around the throttle and pulling tight onto the other handle bar. Theory was to evaporate unburnt fuel.
  • Got seat on and the rear body bits.
  • Seemed to start ok. Rode it down to the gate and it stalled and wouldn’t start. Tried the rag trick again and got it started.
  • Gave it a good ride and it seems much easier to start now.

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