Project 2KR FZR250 project

Hi again all
Haven't really gotten my teeth into it yet, but here's how my 2kr rebuild is going:

- bike purchased, delivered & parked in shed
- prelim stocktake done, missing parts identified so far are ignition key, windscreen, body fasteners & one engine cover.
- Have ordered replacement key with ignition barrel & tank cap to suit. $50 on ebay, so we'll see how that goes. Have also ordered beginner lock picking kit to get existing tank cap out.

Some pics of how it was delivered:

 

Successfully picked the lock on the existing fuel cap - a bit easier than I thought it would be! Reckon it was probably pretty worn for that to be the case.
Also replaced the ignition barrel - the new one had a plug while the existing one didnt, so put a three wire plug in the loom to match the new barrel, and used a single connector for what I assume is the earth.

Which brings me to the other problem - the wire colors weren't an exact match. The new barrel had Red, Green, Black, & Black with white stripe. The bike has Red, Green, Blue & Blue with red stripe. For now I've assumed red to red, green to green, black to blue, black with white stripe to blue with red stripe. I'll double check this another day with a battery.

If anyone knows these wire colors (on the bike that is) and I've gotten them wrong, I'm colorblind so feel free to correct me.

 

Looks like I've wired up the bike correctly. Dash lights came on with a battery last night. Wasn't the time to hit the starter, didn't have a battery the terminals could be fastened to, I was just holding them on by hand. Would like to replace the oil before I do that also.

 

Finally cracked the carbs open last night. Going to give the jets a quick clean out, splash some fresh fuel in her (tank seems quite clean after first clean out) and once I change the oil and fit the plugs, see if she starts when I kick her over the first time.

 

We have a starter:

https://youtube.com/shorts/SgNreDqox9M?feature=share

(apologies, the embed function doesn't work for this video for whatever reason)

 

Yeah definitely doesn't sounds great. I've just ordered a full set of carb seals from you today, will take them apart for a full rebuild (not just a quick cleanup of the jets) and hopefully that'll fix what's going on. If not, top end and barrels come off for a set of rings and valve seals, which I'll probably do anyway given the blue smoke pouring out.

That's bloody clever, thanks mate

 

That's fantastic detail, thanks so much. I have been looking over the photos and threads of people rebuilding the carbs on here, and being my first 4-carb rebuild I'm going to go as slow and methodical as I can, reading and re-reading everything, including your site (I'm sure the wife won't mind my $500 bike sitting in her car spot for a while yet).

Haha with some of the engineers I've worked/studied with, this doesn't necessarily mean competence at all

Thanks again mate

Jake

 

Could also get some eye-rolls by pointing it at the wife and telling her she's a certified hottie.

 

After quite a while of the bike just sitting not being worked on, I pulled my finger out over the christmas break and gave the carbs another going over, putting each in the ultrasonic cleaner, and blowing out all jets and passageways. All 4 cylinders run great now, but the bike will only rev up to 8-12k, seems like a fuelling issue, with not enough fuel flow to maintain more than 1/3 or so throttle. I'm thinking I'll be checking the fuel float height when I get home tonight, then following that who knows.

Both calipers are seized in place, but luckily a while ago I read on here the first get R6 caliper bolts straight up to the 2kr fork - I can confirm this is the case, and I now have a front brake while I await my caliper piston removal tool.

With the engine running and a front brake, I took the little bike down the street under its own power for the first time. I'm very excited to get this project done and ride this bike through Kangaroo Valley and Macquarie Pass, the engine feels good and the bike feels very flickable. I'll post a video of it running soon.

 

https://youtube.com/shorts/bNt3IOzc2hA?si=d4BQaX9i-4Xbzimx

Above vid is of the bike running and revving as hard as it can, maxes out at 13k, and I twist the throttle harder, but revs fall. This is what always happens, maxing out anywhere from 8k to 13k.
Thinking this is the fuel pump maybe? A new one is $50 ish delivered so worth a try I guess.

After the vid was taken I checked the mixture screws in the carbs, 1 & 4 where 1 turn out, 2 & 3 were 2 turns out, changed all to 3 turns out.
Also welded up the broken front fairing support, and fitted the gauges, moved the headlights into the new plastic bracket and fitted to the bike (after the video).

New parts required are:
Gauge plastic bracket (current one has plastic at mounting points broken, is being held in by the mount points on the metal cover)
Rubber grommets at back of speedo & tach.
New air filter (Anyone had any luck with these?)
Headlight globes (standard H4's don't fit, supercheap look like they have some).
Tail light globes
Both right hand blinkers
New tyres
Chain & sprockets (purchased)
LHS engine cover fairing (Might have better luck with a whole fairing set from Aliexpress honestly).

Once all that's fitted I think we'll be off for a blueslip.

The more I get into this project, the more I realize this isn't going to be a ground up as new resto. There's just not enough value in the finished bike for that. So it'll stay ratty I guess. Functional and working 100%, but not looking to win any trophies for sure. At least that way I'll feel less precious about having proper fun on this thing.

 

New fuel pump didn't fix the revving issue, but as the bike was idling, I noticed some magic blue smoke escaping from somewhere. This connector from the regulator rectifier is getting a bit meltey, so I'll replace the connector and hope it was a short causing it.

Unsure if it could be, but hopefully this is the cause of my revving issues.