1992 ZXR250C Kawasaki Ninja

Hi guys,

I would like to make a thread showing the things I have done and would like to do with my ZXR250. This is my second bike. It is the first 250cc I have owned. I am learning every step of the way. I want to share my work because it might help others and I can get some help along the way. I hope you enjoy and the info is useful.

 

After one week of owning the bike I found I had ridden over a screw somewhere. I got it fixed straight away. It cost me $65 for them to plug the hole.

Here are some before photos:


And here is the photo after:-

 

I was looking for a slip on for my bike. I had seen that there are very few inexpensive slip ons available for this bike where you don't have to cut or weld your header pipe or flange in some way. The Tyga slip on looks great, but it comes with a price.

I found a Gianelli slip on at MCA's for $50 which has a three stud pattern. The header pipe part after the flange slid right in perfectly. The problem was the holes on the slip on didn't match with the holes on my header pipe flange. Instead of trying to modify my header flange, I thought it was a better idea to drill new holes in the slip on and thread them my self.

Here is the exhaust:-


To do this it was very simple.

We put the Gianelli exhaust on to the header pipe. Rotated it slightly. Made points where the new holes should go so they would match up.

We then measured the bolts that were in the previous exhaust so we could use those for the new holes we were about to make as the bolts that came with the Gianelli were to big for the header pipe flange and I did not want to make the holes bigger.

The old bolts were 5.8mm from memory.

Drilling into the Gianelli exhaust we made pilot holes with a 3mm drill bit. Then used a 5.5mm drill bit. :-

Then after that. My friend used his tap and dive threading tool to make new thread. I cant remember what size he used. I had never used a tap and dive threading tool before. It was actually quiet pleasing how simple it was.

Now the exhaust fits fine. Here are some photos of how it looks now:-

 

Decided to check the air filter and spark plugs on my bike as there was some issue and it wasn't revving all the way out to 19000rpm. It was struggling after 14000rpm. Long story short, the spark plug on cylinder 1 wasn't screwed in properly. Also the lead connecting to the spark plug on cylinder 1 was not on correctly. The leads clip on to the spark plug as per usual. The rubber on the lead is then able to be tightened slightly by rotating it.

The bike now revs out to 19000rpm. Although it does struggle slightly after 16000rpm.

Checking the air filter.

The air filter was clean. No problems there. We then noticed there were no gaskets from the air box to the carburetor. Also there were only four bolts holding the air box to the carburetors. Someone had also managed to snap three bolts into the holes. Here are some photos.



So I plan to now remove those bolts by drilling into them. Making thread the opposite way so I can use a tool that screws in to the left. So when it gets tight in the bolt I can then continue turning it to the left and it will hopefully un screw the bolts that are in there now.

Then I will buy some new gaskets for the carburetor to air box or make my own. I haven't yet found any online for this bike.

 

Thanks mate. I am purchasing those air box seals now. Thanks for the link.

Those guys were great help. My friend with the black hat has been so good. Helping me with everything. Sensational workshop lighting.

 

Thanks for the link.

 

We will see how it goes once the air box to carburetor gaskets are in. Will keep you posted.

It isn't much louder. The sound quality has greatly improved. Slightly deeper booming sound to it. I will post a video soon.

I was very happy with the simplicity of it. Job was done in 30 minutes or so.

 

When I get the gaskets I will do it and take photos and all that. I will have a look for your post on how to do it.

 

That is simple enough as well. Thank you very much guys.