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Project Linkin's FZR250R 3LN3

Discussion in 'Your 250cc Projects' started by Linkin, Jan 31, 2015.

Page 15 of 37
  1. Phil

    Phil Senior Member Contributing Member

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    Do you think that the guide is worn out, very possible indeed. I have been racking my brain to recall what I did with the rebuild I did on Chris's zxr250. Both guides were worn but still useable. Life wasn't meant to be easy.......who said that:lolsign:
     
    Phil, Mar 14, 2015
    #281
  2. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Well I have to go now to see a man about a wallaby.
    Catch you blokes tomorrow. Remember Occam's Razor, the simplest explanation is usually the right one.
     
    maelstrom, Mar 14, 2015
    #282
  3. Joker

    Joker See "about me" for contact details. Contributing Member

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    But also don't forget Murphy's Law. Geez I hate that guy.
     
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    Joker, Mar 15, 2015
    #283
  4. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Cam chain... done!

    Prep from yesterday, plenty of access with the carbs, airbox, radiator and rubber engine cover gone. Had no issues there

    [​IMG]

    [​IMG]

    [​IMG]

    That is where we left it while we waited for the fizzer factory's engine internals mastermind to arrive (ie, he's done timing on cars before) - @Grasshopper

    This is what your timing marks should look like. The T is under the stator cover. The dimples are on the cams and cam guides. When these all line up, you are at TDC for Cyl #1 on the compression stroke - no valves open

    [​IMG]

    [​IMG]

    [​IMG]

    Your cam chain should have 6 links between the cam sprocket teeth that are facing "upward" - in the sense of where the engine is pointing.

    [​IMG]

    EMGO chain breaker kit cam in very handy. Would not have been able to do this job without it.

    [​IMG]

    Pin out of the new chain

    [​IMG]

    Wiring up the old chain to keep it in place. Cam chain tensioner is out at this stage (not that it mattered, because the chain was rooted. Stretched by 5mm)

    [​IMG]

    Old chain apart

    [​IMG]

    After this we removed the cam guides, cams, joined the new chain on & fed the old one out, got the crank to the T mark, replaced cams, & joined the chain

    This is what we ended up using to hold the pin in place. Zip tie on the pin, which ended up on the rod pushing the pin in.

    [​IMG]

    New chain in but slack, still has 6 links between the cam sprocket pointing upwards (in relation to engine) - tensioner out

    [​IMG]

    And of course, celebration of a job well done!



    Click to watch video

    BONUS: CEO of Fizzer Factory sleeping on the job!

    [​IMG]




    [​IMG]


    Fin.
     
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    Last edited: Mar 15, 2015
    Linkin, Mar 15, 2015
    #284
  5. Mclaren

    Mclaren Well-Known Member Contributing Member

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    Wearing apprioate safety gear I see lol
     
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    Mclaren, Mar 15, 2015
    #285
  6. Phil

    Phil Senior Member Contributing Member

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    Bravo and well done guys, have you know that we have been waiting all day to hear the outcome.....worth waiting for :lolsign:
     
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    Phil, Mar 15, 2015
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  7. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Ta Da! Well done!
    All without any bent valves. I have to assume the valve clearances were all good then.
    How did you peen over the pin when you assembled the new chain?
     
    maelstrom, Mar 15, 2015
    #287
  8. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    We didn't look at the valve clearances, not enough time.

    The chain breaker kit had a tool to peen the pin. It basically crushes the end of the pin while you are putting it back in the chain.

    We did a quick tune on it as well, which helped. Just don't ask me about that F$%^ing airbox!!
     
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    Linkin, Mar 16, 2015
    #288
  9. kiffsta

    kiffsta Senior Member

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    well done lads :thumb_ups:
     
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    kiffsta, Mar 16, 2015
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  10. Grasshopper

    Grasshopper Well-Known Member Dirty Wheel Club

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    Yeah, we took our time and made sure all was right along the way. Thanks to @maelstrom for recommending to take the cams off when at TDC, which leaves no chance for error when re-assembling etc. Bit fiddly when refitting the cams and putting the chain back on the right position... but checked and double checked everything.... and all good... Linkin has just left for Sydney... If he makes it home, we can assume success!
    :lolsign:
    And thanks to Greyimport for supervising and making cups of tea and use of the Fizzer Factory!
     
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    Grasshopper, Mar 16, 2015
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  11. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    You guys scared the bejesus out of me there for a moment.
    You better write a Howto for the tech forum from this episode.
     
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    maelstrom, Mar 16, 2015
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  12. Moo

    Moo Plodge Racing!!!

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    oh ya kids!!
     
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    Moo, Mar 16, 2015
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  13. Grasshopper

    Grasshopper Well-Known Member Dirty Wheel Club

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    Linkin and the bike made it back to Sydney with no dramas! So all is well...:thumb_ups:
     
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    Grasshopper, Mar 16, 2015
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  14. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    As an addendum - cams out and rotating the crank to fit the new chain.

    [​IMG]

    [​IMG]

    [​IMG]
     
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    Linkin, Mar 16, 2015
    #294
  15. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Right, so with the cam chain out of the way, the next thing to do is the carbs. The litetek stuff will take a few weeks to get here from Thailand, but I got my Keyster kits for 3LN1 carbs in the mail today. Too dark to do anything today but tomorrow arvo I will have a go at replacing the needles and emulsion tubes. Hopefully will not tear any of the gaskets.

    Someone remind me what needs to come apart to get to the needles and emulsion tubes?
     
    Linkin, Mar 17, 2015
    #295
  16. Grasshopper

    Grasshopper Well-Known Member Dirty Wheel Club

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    Just refer to the Grasshopper 3LN3 thread...
     
    Grasshopper, Mar 17, 2015
    #296
  17. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Successfully changed out the needles and needle jets for new ones. Replaced a few gaskets where necessary.

    Causalities:

    Choke cable holder on carbs - hole threads are rooted and I dropped the little holder piece. Have to manually hold the choke now.
    Decelerator cable broke off on the throttle grip. Removed it. Throttle feels better. It was hanging due to the decelerator cable before.

    About to go for a test ride... will let you all know how it goes
     
    Linkin, Mar 18, 2015
    #297
  18. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Fuel economy report

    106.2KM / 4.83L

    21.987KM per litre, which is 51.74 mi/gal (MPG)

    Amazing how much a little bit of wear on the needles and emulsion tubes just puts your fuel economy down the crapper. With this current fuel usage I could do about 200KM before hitting reserve
     
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    Linkin, Mar 20, 2015
    #298
  19. Phil

    Phil Senior Member Contributing Member

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    Good for you mate :thumb_ups: That is 100% better than what you quoted us prior. Let's be honest most of us want a break after a 200k's, called num bum!!!!
     
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    Last edited: Mar 20, 2015
    Phil, Mar 20, 2015
    #299
  20. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Another win!
    So are you going to go back the to the Fizzer Factory to be schooled by the master in setting pilot mixtures by ear or have you conquered that too?
     
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    maelstrom, Mar 20, 2015
    #300
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