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Project I have gone over to the Dark Side ... ZXR C2 Model Stealth Edition

Discussion in 'Your 250cc Projects' started by GreyImport, Feb 5, 2014.

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  1. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Another grand job by the "Home Harness Company"

    This makes it nearly complete enough to try and start it :cool:

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    GreyImport, Dec 26, 2021
    #461
  2. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Looking good there Cheify.
    Hopefully 2022 will be the year that all that hard work gets a good time at the Dragstrip


    Sent from my iPhone using Tapatalk Pro
     
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    Andych, Dec 26, 2021
    #462
  3. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Bling me up buttercup

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    GreyImport, Feb 12, 2022
    #463
  4. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Thought I would investigate running the bike at the drags with the crack in the fork as I cant pick up the spare ZXR I bought for a month or more (long story) , to replace it.

    But its certainly more than a 'crack' :cool:

    IMGP0129.JPG


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    GreyImport, Feb 13, 2022
    #464
  5. thebeefsalad

    thebeefsalad Well-Known Member

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    the bolts will hold it in place, but something tells me that wouldn't pass scrutineering
     
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    thebeefsalad, Feb 13, 2022
    #465
  6. risky

    risky risky

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    could it be tig welded?
     
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    risky, Feb 13, 2022
    #466
  7. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Its been self scrutineering with covid but may be back to normal now
    Either way I give it a fail anyway ..... its only in a straight line at 100kmh+ but I could do without a face plant into an airport runway :)

    It will be easier to wait for the other ZXR to arrive and swap it out .... Ill brush the cobwebs off the FZR for Gunnedah
     
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    GreyImport, Feb 13, 2022
    #467
  8. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    I think the only way to fix that via welding by to cut/grind the broken section flat, weld in all new material with a steel plate keeping the gap correct, then drilling new holes for the bolts. It'd be stronger than the original cast metal, but no idea how long it would last, or if it would even work.
     
    Linkin, Feb 13, 2022
    #468
  9. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    With that tack welded on the inside edge where the axle goes, then material removed to form a VEE, root pass, then filler passes - that could be tig welded back up to be stronger than originally
    4000 series filler rod is specified for cast materials
    Then the axle hole and bolt holes reamed back to size
     
    ruckusman, Feb 13, 2022
    #469
  10. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    It sounds easy but what would be the cost to have it done? That sort of welding needs good (very good really) welder with a machine that can have all the settings set just right... then be suitably cleaned and degreased.. that is befoe a weld bead is run. Then you would need to ensure the hole is in perfect alignment as well as the bolt holes and tightening gap is correct... An expensive exercise and not one suited to a back yard repair.
    As @GreyImport said...he has a spare set coming so it isnt like there isnt an alternative.. and in the end... it is a drag bike, not a daily transport.
     
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    Andych, Feb 13, 2022
    #470
  11. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Stage 1 of the frontal lobotomy

    Fork oil wasnt even that bad .... seen far far worse

    It even got 15 mins of sunshine in the exercise yard during the "workshop" reshuffle

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    Last edited: Feb 18, 2022
    GreyImport, Feb 18, 2022
    #471
  12. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    The good fork back in with new oil

    Drop on the front end of about 30mm

    DSC_0200.JPG

    Didnt bother changing the seal and boot .... just a touch up with the "Seal Doctor" and a few wacks with the seal driver.
    Wasnt too flash when purchased , but time will tell :D

    ZXR fork oil leak.jpg
     
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    Last edited: Feb 19, 2022
    GreyImport, Feb 19, 2022
    #472
  13. Grasshopper

    Grasshopper Well-Known Member Dirty Wheel Club

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    Wow that's looking impressive :thumb_ups:
     
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    Grasshopper, Feb 22, 2022
    #473
  14. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    So looking into a replacement TCI unit
    Id forgotten how crappy the original is .... to look at anyway

    The Lixianda looks the choice

    https://www.lixianda.com/products/KAWASAKI/728.html

    https://www.aliexpress.com/item/538863640.html

    It has all 10 connections even though it looks like the 4 pin plug is the important one for the coils

    https://www.ebay.com.au/itm/3830418...ame,chnl=mkcid&ul_noapp=true&autorefresh=true

    @Linkin .... can u remember which one you bought ?



    Anyone know what the significance is of this letter?

    TCI numbers.jpg


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    Kawasaki ZXR250C Wiring Diagram.jpg


    Kawasaki ZXR250A-B Wiring Diagram.png
     
    GreyImport, Mar 23, 2022
    #474
  15. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Anyone know what the significance is of this letter?

    Not sure. I thought it was the TCI release order, but that's incorrect. Maybe just an easy identifier instead of quoting the entire part number?

    That TCI (21119-1322) you have & 21119-1384 were used on all the 250C models from the C1 to the C7. I've read that some of the Malaysian 250C bikes (240kph speedo) used the Balius TCIs (21119-1316 & 21119-1383), but that's another story.

    21119-1384 ZXR250C CDI.png

    Plus configuration for you...

    ZXR250C TCI Wires & Colours.JPG
     
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    Last edited: Mar 23, 2022
    Frankster, Mar 23, 2022
    #475
  16. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    I bought the Lixianda unit from aliexpress. I can't recall exactly, but they had two versions for the C models I think.
     
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    Linkin, Mar 23, 2022
    #476
  17. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    ... and I bought one for my Honda directly from Lixianda.
     
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    maelstrom, Mar 23, 2022
    #477
  18. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Hmm Chinesium Electronicals... lets hope they put in the correct amount of smoke....
     
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    Andych, Mar 23, 2022
    #478
  19. jmw76

    jmw76 Well-Known Member

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    Don't look too carefully. Just about everything is Chinesium these days.
     
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    jmw76, Mar 23, 2022
    #479
  20. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Yes I can see it there .... I was just looking today to find a good mounting point on mine .... there's a lot of space under the "pillion seat" area for a mount plate. Did u just unpeel the loom and run the appropriate wires/plugs to the front?

    Yes, is the short answer. I don't run a charging system on the race bike, so no R/R to worry about. There is also no Fuse Box as Murdo did the wiring to run through a single 30amp fuse. The Lithium battery is right next to the TCI. All the wiring is forward of the frame cross beam (including the starter).

    Front.JPG
     
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    Frankster, Mar 23, 2022
    #480
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