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Project Kawasaki ZXR250A - Project Mantis

Discussion in 'Your 250cc Projects' started by kiffsta, Apr 10, 2021.

  1. kiffsta

    kiffsta Administrator Staff Member Contributing Member Dirty Wheel Club

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    90 CBR250RR, 1973 Suzuki GT380 and a 1995 CBR900RR
    I recently purchased a 1989 ZXR250A off @James Mclaren , close to 97% complete and came with a brand new green chinese body kit. I compression tested the motor and all 4 pots were over 140 psi cold, carbs were stripped and cleaned and she did start and run. The compliance plate is missing , but a spare frame has been supplied and is clear. While the yellow wheels are cool, paint scheme for the bike will be Kawasaki green and silver or Kawasaki green and black, am on the fence on that one.

    I have always wanted to do an A model , but finding them is nigh on impossible, so when James offered me this one, I jumped at it. I had plans of a full OEM spec build, but alas the body kit is already painted green , I cant in good faith spend silly money on a paint scheme, when its already painted.

    I have chosen the call this one Project Mantis , as the Wasp was already taken\, but in doing so, I am respecting the Insect naming convention , I do feel for the member who embarks on project stink bug :thumb_ups:

    I have set a budget of $1500 plus the purchase price, will I make that ? ... not sure but will try

    I have just ordered :
    • Steering head bearings 22-1025-1
    • Fork seals
    • Fork Dust Seals
    • Sprocket 14
    • Sprocket 48
    • RK CHAIN 520VRX x 120 LINK
    • Air filters - uni filter NU3306 or similar
    • Oil filter KN303
    • 3 x FERODO Brake Disc Pad Set - FDB508 P
    I will order some Dunlop Alpha 14's and 90 degree valve stems next week.

    I have these in my basket with Wemoto, I have a credit with them, so I wont order until they adjust my invoice.

    Kawasaki ZXR 250 (ZX 250 A1) (89) Handlebar Grips - Pair (Design Type - OE Style)
    Kawasaki ZXR 250 (ZX 250 A1) (89) Gear Lever Rubber
    Kawasaki ZXR 250 (ZX 250 A1) (89) Fork Oil Seals Pair
    Kawasaki ZXR 250 (ZX 250 A1) (89) Sprocket Carrier Bearing
    Kawasaki ZXR 250 (ZX 250 A1) (89) Rear Wheel Bearing Left
    Kawasaki ZXR 250 (ZX 250 A1) (89) Rear Wheel Bearing Right
    Kawasaki ZXR 250 (ZX 250 A1) (89) Clutch Cable by Slinky Glide
    Kawasaki ZXR 250 (ZX 250 A1) (89) Front Wheel Bearing Kit


    Roller
    I will paint the frame, swing arm, and subframe in silver , wheels will be stripped and painted, new tyres, I am looking for a 2006 onwards R6 rear shock and an OEM brake master , brake lines etc

    Brakes
    I need to source brake master, brake lines, levers, I will order new calliper seals, paint the callipers, bleed the brakes etc

    Engine Clean up
    While it would be nice to vapour blast the engine, I don't have the time or inclination to strip and rebuild it, with such good comp readings, I think that will be silly. So a good rub and scrub should suffice , side covers will be cleaned and painted. Fit new oil filter and mount the engine into the frame.

    Fuel
    I have 2 sets of carbs and a 95% complete litetek kit minus the air fuel mix rubber and metal washers , I will make one set of carbs from the 2. The tank is going off for paint and will be matched to the body kit with a ZXR decal. I will strip and clean the petcock as it is probably gummed up.

    Exhaust
    I have already sandblasted the exhaust headers and cleaned all the rust off, I have applied 2 coats of VHT silver heat proof paint. I don't have a muffler , an OEM one would be nice, but I have a few issues finding anything apart from Tyga


    So how can you help ? , I'm glad you asked , I need a few ZXR250A parts , here is what I am chasing :

    1. ZXR250a OEM Front brake master
    2. Muffler - OEM , may purchase aftermarket if need be
    3. Fairing side infill panels for an A model
    4. Brake lines (front)
    5. air fuel mix screws metal and rubber washers - Litetek preferrred
    6. Decals, I need a tank decal and some inspiration for the rear side fairings and lower fairings , I will most likely dust of the Vinyl cutter and see what we can do.
    7. ZXR250A seats with good vinyl - mine need recovering so If I can find some good used ones, I will buy them

    We that's about it for the moment , I am pretty excited to bring this old girl back and give her a new lease on life.

    Will post some pics from James as he bought it for reference.
     
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    Last edited: Apr 10, 2021
  2. kiffsta

    kiffsta Administrator Staff Member Contributing Member Dirty Wheel Club

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    As James bought it


    A6E569D2-D95B-4C50-B495-C4E3577BC9F7.jpeg D28DFD6D-E8A0-4777-96AD-4F731E24C683.jpeg


    Headers
    C800C09A-08C4-44B5-9C71-EAE0C2AB1F14.jpeg 4A17C4F6-8FDF-49B1-8B29-7B985E9B80BD.jpeg A2070BE2-5E05-4FB5-8908-6DAF20EFEA59.jpeg
     
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  3. kiffsta

    kiffsta Administrator Staff Member Contributing Member Dirty Wheel Club

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    I have managed to get a vector image so I can cut the tank decal out of vinyl, I am still playing with colour options, but I am hoping someone with an A model tank with the decal on it, can measure the length for me so I can cut the correct size

    tank_zxr.jpg
     
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    Last edited: Apr 10, 2021
  4. kiffsta

    kiffsta Administrator Staff Member Contributing Member Dirty Wheel Club

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    Well, I have come to the realisation that I can’t do this at home , I don’t have the tools or machines to do it so it is on the bench getting the royal treatment at the shop.

    frame , swingarm and subframe have been blasted and painted. Wheels have been blasted and off at the painter as I want a really nice finish

    I ordered a few consumables such as fork seals ,dust seals, wheel bearings , chain and sprockets , brake pads so that is keeping me busy.

    I managed to source a 2007 r6 rear shock in Melbourne so that is on its way to me

    There has been lots of cleaning and painting and getting ready to get her back to a roller. I ordered my Dunlop alpha 14’s , should be in today.

    I did hit a snag , headstem bearings are different between the 2 a model frames I have here, I am quite perplexed by this , I have sent the lads to the bearing shop to see what they can supply.
    598ED105-0654-4EFE-8118-0E1EF29E2E87.jpeg 4A32EF81-F683-40CB-8487-8473CEF4A61D.jpeg 07DF0D23-E842-46B9-884E-7F959B8ACD9E.jpeg 4C07B2C7-DA9B-4284-B46B-AE8FE37C1960.jpeg E8776037-5F9A-4DDE-9318-17E34CB744B8.jpeg 45A0D74B-7650-4DCF-9D37-986AFAF3DA1A.jpeg
     
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  5. kiffsta

    kiffsta Administrator Staff Member Contributing Member Dirty Wheel Club

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    Bit more assembly today with the engine now installed , front forks, triple, headlights and gauges now installed.
    We found the correct head stem bearings at a bearing shop $26 for the pair

    I should have my wheels back on Tuesday from the painter , I couldn’t find an a model brake master , so a c model one is being used along with c model brake lines. I located some infill panels in Japan and they are coming soon. Mulfler is sorted, @james hooked me up with an oem one, had a few scratches, but I have been sanding and polishing and it’s almost there.

    My wemoto order arrived as did my Dunlop alpha’s and a new air filter so it’s game on

    I keep saying this one will be my last one for a while then tonight I go out and buy 16 bikes, one of which is a zxr250c.

    I guess tomorrow is van day, picking up bikes AC92BD08-D6FD-477F-BF3E-A4D2C85BEB27.jpeg 21D296C0-A5F3-4FF2-A849-C948FC6B247A.jpeg
    FB125F06-FD74-4BA9-94BF-D7AE252D8E68.jpeg
     
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  6. kiffsta

    kiffsta Administrator Staff Member Contributing Member Dirty Wheel Club

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    R6 rear shock is in, it Fowled on the battery box and I had to remove some plastic.

    exhaust is on , starting to look like a bike again


    7D07F68B-3007-40B2-93DD-E6B4A020CD13.jpeg 42790A13-27CA-4F64-87DA-116452694B6C.jpeg
     
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  7. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  8. kiffsta

    kiffsta Administrator Staff Member Contributing Member Dirty Wheel Club

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    Thanks for that , I’d like to lodge a formal protest , those wheels are temp ones while mine are off getting painted , it is possible to appeal my 99 year sentence , or am I flogging a dead horse ?
     
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  9. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    "Temp roller wheels for photography purposes" .... Ill have to check with the Clubs constitution but I think your appeal may be granted after the final reveal of this bike

    Newly painted wheels ... bah humbug .... takes all the fun out of it :fuckyou:
     
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  10. kiffsta

    kiffsta Administrator Staff Member Contributing Member Dirty Wheel Club

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    B15A0BEF-84F9-4885-9DB9-D5D09CBFB690.jpeg 0C1F1EF7-CD10-466C-9B7E-AA490BB3D320.jpeg All wired up except the coils , I am going to check the leads and caps before final fitting.

    the coolant hoses are in a real state, I found some c model hoses and they appear to fit

    tomorrow is carb day , I have a sparky wiring up some 3 phase points for the polisher machine, so I might as well knock them over while I wait foe him to do his thing. A mate had some air fuel mix seals which completes my litetek kit so I’m all good.

    I am absolutely loving this zxr, it has been so long since I played with an A model, the last one I had was 8 or 9 years ago. I kind of forgot how ahead of their time they were.
     
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  11. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    All done in a matter of days, brilliant.
     
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  12. kiffsta

    kiffsta Administrator Staff Member Contributing Member Dirty Wheel Club

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    and.. its carb day, Litetet kit and a can of threebond engine conditioner in hand, lets go
    CDEBF1BE-4D71-45C2-B46E-FA4DC81814BD.jpeg

    9B54753E-8A5B-4A26-A52C-D9D24AD1334A.jpeg
    I love these Litetek seal kits, they make this crappy task so much easier although I missed one of the fuel t piece and had to contact the Litetek help desk for some guidance, the joys of getting old and having crap close up eyesight, even with my trusty glasses on, I missed one of the old seals.
    01A84F4E-D64D-4E84-93BC-C7EEA6753D97.jpeg
    all that's about all I can do on the carbs, I have some new fuel valves on their way , hopefully they arrive monday and I can finish them off.
    69A674BD-501F-47AD-964A-11A1E01B9982.jpeg
    Almost all of the seals that came out were perished
    30FF2C1B-F8C0-4CE0-B54C-90465871B48A.jpeg
    Pic from my Painter mate, they look sweet
    0E714DD1-7B78-4DCD-AA27-9950B06EC2E4.jpeg

    D2A4EE84-4677-4102-89E7-0A59D29BC337.jpeg
    Nose cone screen and indicators are on , Im quite pleased with the progress.
    E710C31E-ABBA-4F4D-A02B-342FFD0911E6.jpeg
     
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    Last edited: Apr 17, 2021
  13. James Mclaren

    James Mclaren Active Member Premium Member Contributing Member

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    I look forward to swinging by and seeing this again soon
     
  14. kiffsta

    kiffsta Administrator Staff Member Contributing Member Dirty Wheel Club

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    Hmm, carb jets....

    my new fuel valves arrived this morning and are now installed, all that is left is to fit the main jets and do the bowls up.

    I checked my main jets are they are 98 and 100 , after messaging @Frankster and checking the A model manual, I know I need 125, 128, 128 and 125 , I pulled my spare set of carbs apart and they are 100, 122, 122 and 100 , some very dodgy jetting going on here.

    Motorcycle Spares Warehouse in Melbourne have jets in stock, so 4 new jets will wing their way to me , hopefully this week.
     
  15. kiffsta

    kiffsta Administrator Staff Member Contributing Member Dirty Wheel Club

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    Alright , got a little bit of play time in, jets arrived and carbs were reassembled and fitted to the bike. Coolant and oil was done and it was time to fire her up , full choke , No throttle and she fired and settled into. an unhealthy idle of 9000rpm, even backing the choke off she was still up that high. Scratched my head and called @ShaneP and @Frankster for some zxr advice . It was suggested to check the carb insulators for leaks as it must be sucking in heaps of air . They old insulators were quite hard so I swapped them out with some spares , much better now.

    She revs cleanly to 18,000 rpm.




    Wheels are back from the painter , tyres are on and she is rolling by herself

    as always , 2 steps forward , one back , my lockset is from a. C model and doesn’t work, I have one off an a model but no barrel, just the base , so I am on the prowl for an a model lockset to get her on the road

    loving this old girl


    05869B2E-5054-4974-8434-B24A545F8B7A.jpeg
     
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  16. kiffsta

    kiffsta Administrator Staff Member Contributing Member Dirty Wheel Club

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    Brakes were next on the list , I sandblasted the calipers and gave them a quick paint job using gold caliper paint. I then fitted new piston and dust seals from wemoto , there was a bit of corrosion on the pistons but I polished them out.

    I also made some tank decals last night on the vinyl cutter , it has been a wee while since I used it. My painter is painting the tank on Saturday and should have the tank back to me on Tuesday.

    I found a fuel leak and somehow I have broken a fuel bowl seal, it must have slipped as I was fitting it , so I reclaimed an old oem seal and it is fuel tight.

    ignition dilemma sorted, I disassembled the c model ignition, removed the lowered section with the wiring and fitted the a model one instead . As old mate Edd Chine would say... result

    296F9C7C-855E-4845-9538-D3A06404667A.jpeg E36F3A62-77DD-4544-8E92-780DB911E014.jpeg A852771C-177D-4496-809E-64F1DD80BD16.jpeg 82C43F69-A780-4132-BDDA-F1F4704CCC10.jpeg
     
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    Last edited: Apr 22, 2021
  17. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Need some nice shiney brake lines and bolts on those calipers to complete the job.
     
  18. kiffsta

    kiffsta Administrator Staff Member Contributing Member Dirty Wheel Club

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    Maybe down the track , she has cost me a few bucks so far
     
  19. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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  20. jmw76

    jmw76 Well-Known Member Premium Member

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    polish them up or paint them black.
     

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