FZR250 Track/Race Revamp Project

So my little FZR 250........

Well after 10 years away from bikes i decided i wanted back in (but not on the road) so bought this little beauty late last year.
Bike has run in P6 Historic’s for the last few years and I’m tempted to maybe run it myself.

So attached is the day I collected the little Fizzer pic's say its clean.......needed a new paint job but meh at that stage im not bothered/fussed........

 

So I did a few trackdays and forgotten how much I had missed bike’s. I got quicker ad quicker and pushed harder and harder and then the inevitable…….i came off. Had a nice low side on a right hand bend at about 90Kph. I ended up with a bruise on my butt but otherwise ok, the Fizzer was doing ok until it flipped when it hit the sand……so attached is the end result:

Cracked and broken fairings front and rear
Dent in the tank (small)
Dent in the frame (small)
Smashed inner and outer stator casing
RH bar end
RH handle bar
Clock frame bent
Exhaust dented

So it prompted me to deal with the much needed TLC as well as the issues caused by the lowside.
So currently on order/need to be got/already arrived:
Rocker cover gasket
Water pump gasket
Front and rear sprocket
Outer stator cover
Inner stator cover
Chain
New bar ends
Oil and filter
Clip on’s (I got a new RH bar but the fizzer fell during a clean-up and added insult to injury by breaking the new RH bar, thanks to Mboddy I now have a new set of clip on’s)
Plugs
Air filter
Tyres
Brake pads
New exhaust

I have made a good start on the fairings and I’ll pop up pic’s of my progress. I fear this bike might end up been one of those never ending but used projects…they ones you always see in primer

 

Cheers Kiffsta, i'll keep it in mind, you seem to be a magnet when it comes to finding bikes, bloody wish it was that easy here in Perth, could do with a spare engine

 

Their cheaper to buy than OEM for 1, they are quick and easy to change should you have a crash and normally weigh A LOT less than OEM bars. you can also get them in different adjustments to suit different riding styles and comfort levels.

 

na not at all mate, Tube size is 38mm so just have a look on ebay, there is heaps of different makes and styles colours ect. handy to have as spares also
Ok so just a little update:
So a few of my parts have arrived (few days ago but hey i forgot to mention that in the first post : P ) so i now have my stator casings inner and outer and new front screen. so with this been the kick up the rear i needed so i have starting the repair process of the damage to the fairings.
So i started with this bit, now if you go back to the first post you'll see the before pictures......this is the afterish...still more to be done with repairs and a lot to be done in terms of sanding.....have i mentioned i hate sanding HATE IT!! need to buy a DA and an air compressor i think

So then while i was fixing my fairings (and a set belonging to my mates GSXR) i decided to experiment and make a mould for stator casing protection.......1st attempt of making a mould worked out well i think, very happy. it’s a little thick for a mould but hey, at least it will stand up to the use and who knows i may use it down the line on the bike, but for now it’s a mould and i plan on cleaning it up and trying to make a few casing covers from it

 

So there was a track day on the 5th of July which also happened to be my 30th birthday. so my lovely lady went and paid for it, one so i would be able to do a track day on my birthday and two.....so i'd clean up the garage and put atleast one bike back together so i did.

So on went the clip on's.....realised after i had them on and all the bike back together that they didnt like my front fairings and just before my angle grinder came into play a right side bar arrived in the mail, still havent recived the ones i ordered from ebay yet....



rockercover gaskit done, water pump gaskit done, service done.....fairings painteeeeeeee na not going to happen...she'll done didnt take pictures of that, so rough and ready she was packed up and off to the track. she is all set and ready to go.....birthday trackday ohhhh yeeee!!!




so during the day i noticed the engine became a bit more knocky then normal, i already had a feeling the big end were on their way out and the aim was to ride it until it got worse but salvageable.......ye na the bike didnt see it that way.....the moment i started to loose power i dumped it into 5th and started to nurse it back to the pits...3 corners to go and bang..happy birthday from your good friend Fizzer...the gift is what you see below




so i havent yet pulled the blok out, i've been a bit lazy at the moment, the furthest i have gotten is pulling the fairing off, the tank off and having a look at the horrible hole i think it might be a grank bolt that came undone and not the bigends......grrrrr, but i'll find out as soon as i pull it out. so this project will draw out a lot longer than one had first thought haha.

 

So i had a free hour last night so i decided to get to work and pull the block out.....at least if its out i might actually get around to doing something constructive

so before we start....can anyone spot the missing bit of my engine



So all fairing and tank-less.........lets get started....


Carbs in......


Carbs out......


On a rough inpsection they do look rotty, i'll have a better look when im bothered/when i have a working engine lol


and the engine is out.....


and the Fizzer is now in the corner....hopefully she wont have to stay there for all that long. i think while the engine is out she may get a spring clean and a spruce up?! we'll have to see.......


so next on the list, when i get another hour or so to myself, is to split the block and see what sort of damage i did.........stay tuned....

 

Ok so i didnt get much more than 10 min to myself last night bit 10 min was all i needed to pull the sump off and see what went bang.......i believe they are the conrod bolts

on a quick inspection it looks like the conrod has just failed? i'll know more when i have the block fully apart but for now i know it is well and truely F**KED!

 

it might just be Murdo, its very mashed out of orignal shape so it might be the conrod cap? i'll know more once i've pulled it all apart...

 

so no pictures but a little update, so managed to have a little more of a poke around the engine over the weekend. so turns out its two holes not just one...... second was hidden by the water pump.

on inspection of the internals, the crank is ******, the internals are ****** from the lumps of metal flying about and when the con rod gave up and i think.......the head might be done for as the 4th piston was on the up stroke when the rod gave way.

so its an engine i need, i believe there will be little with regards to internals that will be salvagable on this one. if your going do it you do it right haha.

i'll post more when i do more