1992 ZXR250C Kawasaki Ninja

Hey guys,

I removed the 3 bolts that were in the Carburetor and replaced the gaskets air box to carby thanks to LiteTek @GreyImport

So step one

We made a point right in the middle of the bolt with a punch. We were gentle. We didn't want to make things worse then they already were.



Step 2

We chose to use a 3mm drill bit as the bolt itself was 5mm. We drilled right in the middle of the bolt. We also used a rag to cover up the inlets so no metal bits would go into them. Then used a vacuum cleaner to remove the excess filings.



Step 3

We then used an easy out to remove the bolt. It was really easy to get out. They lived up to their name. I found that applying a lot of downwards pressure helps the easy out to bite in the bolt. We made sure that it was dead straight as to not break the hole we drilled into the bolt. There wasn't much room for errors.





Step 4

We then used a re threading tool to clean it up.


Step 5

I purchased 8 new m5 bolts to replace the old ones. I checked that all the bolts went into the thread before putting the air box on.

Here is what the carbies looked like after removed bolts





Those photos are from before we cleaned up the thread.

 

I did an oil change and an oil filter change on the bike. I purchased Silkolene 10w-40 semi-synthetic specifically for motorcycles. I was told not to purchase an oil with additives as some are for non-friction purposes for cars. Because it's a wet clutch the additives would destroy the clutch. I hadn't thought of that. That was the advice from the sales man at Woy Woy repco. He didn't have the right oil for my bike so I went to Super Cheap Auto in West Gosford and purchased the oil there.

I topped up the brake fluid. It was very clean and didn't need replacing.

As to the bike hesitating slightly after 16000rpm. After checking all other aspects of why this could be happening. Weak spark, spark plugs not being in properly like last time, worn spark plugs, broken leads, broken coils, faulty CDI, the butterflies on top of the carbies not opening properly, cam timing not correct etc. We have an idea. The needle in the carburetor could be worn right down letting in far too much fuel making it extra rich at higher rpm. I will be taking the carburetors apart and rebuilding them soon. I am really excited because I have never opened a carburetor before.

 

Will do.

 

I will do that as well. Thanks mate

 

@Th3_Huntsman

I finally recorded the sound of the exhaust. Here it is:-



And here is a video of it going by:-