1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

Project Little ZXR250 project

Discussion in 'Your 250cc Projects' started by pete05, Jan 4, 2020.

  1. pete05

    pete05 Active Member

    Messages:
    54
    Likes Received:
    26
    Trophy Points:
    88
    Joined:
    Dec 30, 2019
    Gender:
    Male
    Location:
    Australia
    My Bike:
    zxr250c, ninja 1000, fz6r
    Well I ended up buying the brake seal bits from my local Kawasaki dealer, price worked out to be about the same as buying from ebay O/S so decided to stay local and I have started the caliper clean up.
    20200318_161558.jpg

    And a few other bits done, motor is back in, seats recovered and muffler polished.
    20200317_151806.jpg
     
    • Looks good! Looks good! x 3
    • Like Like x 1
  2. pete05

    pete05 Active Member

    Messages:
    54
    Likes Received:
    26
    Trophy Points:
    88
    Joined:
    Dec 30, 2019
    Gender:
    Male
    Location:
    Australia
    My Bike:
    zxr250c, ninja 1000, fz6r
    So its been a while but progress has continued, recently bought some new tyres for the old girl some nice Dunlops, I also bolted the old yellow fairings back on just for a look as I had never seen it all complete.

    With the bike recently running I found it has a nice leak from the oil pump so I have just stripped that down, I was able to get the oil pump seal, water pump gasket and water pump mechanical seal kit from Kawasaki but had to go to grey import for the oil pump O ring, hopefully I will have that rebuilt in the next week.

    My recent trolling of gumtree I managed to pick up some replacement fairings and fuel tank for a fair price as mine had seen better days, Im just doing some tidy up work on them now the colour scheme is definitely a change from the yellow, hopefully it will be on the road soon.
    20200416_190358.jpg
    20200405_120729.jpg
    20200405_120920.jpg
    20200405_121001.jpg
     
    • Looks good! Looks good! x 6
    • Like Like x 2
    • Winner Winner x 1
    • Nice Work Nice Work x 1
  3. pete05

    pete05 Active Member

    Messages:
    54
    Likes Received:
    26
    Trophy Points:
    88
    Joined:
    Dec 30, 2019
    Gender:
    Male
    Location:
    Australia
    My Bike:
    zxr250c, ninja 1000, fz6r
    If anyone a spare new oil pump O-ring or knows where I can get one in Australia I would be keen to buy one, I had one on order but have just be informed it's an 8 week wait.

    Part number is 92055-1437
     
  4. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

    Messages:
    4,313
    Likes Received:
    2,383
    Trophy Points:
    898
    Joined:
    Jun 18, 2016
    Gender:
    Male
    Occupation:
    Panel Beater, Spray Painter, Custom Fabricator
    Location:
    Adelaide, South Australia
    My Bike:
    Yamaha's , 1990 FZR250R 3LN3 , 1986 XT250TS 57R , 1984 IT200L 43G, 1976 IT400C 510
    Take the o'ring and oil pump to a decent bearing shop, they should be able to match one up
     
  5. pete05

    pete05 Active Member

    Messages:
    54
    Likes Received:
    26
    Trophy Points:
    88
    Joined:
    Dec 30, 2019
    Gender:
    Male
    Location:
    Australia
    My Bike:
    zxr250c, ninja 1000, fz6r
    Yeah I got it sorted out today thanks, started the bike up and no more oil leak which is nice.
    I spent the afternoon rebuilding fuel tank locks and trying to make up a decent front brake lever that works properly, I bought a new front lever from motorcycle spares warehouse but the part of the lever that pushes on the master cylinder pin is to short which allows the lever to travel to far, if I can't get it the way I want I might have to go genuine.
     
  6. pete05

    pete05 Active Member

    Messages:
    54
    Likes Received:
    26
    Trophy Points:
    88
    Joined:
    Dec 30, 2019
    Gender:
    Male
    Location:
    Australia
    My Bike:
    zxr250c, ninja 1000, fz6r
    More progress today, worked on fitting up the fairings, I have to say for a 30 year old bike that's probably been dropped more times than I want to know it was a real challenge to get everything lined up.
    I managed to get every rubber and clip from Kawasaki to make this all go back together, wasn't cheap but at least it is done properly.
    Still plenty to do before rego but it's progress. 20200529_165916.jpg 20200529_165929.jpg 20200529_165944.jpg
    20200528_143925.jpg
     
    • Winner Winner x 4
    • Nice Work Nice Work x 3
    • Looks good! Looks good! x 2
    • Like Like x 1
  7. Frankster

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

    Messages:
    3,979
    Likes Received:
    2,207
    Trophy Points:
    923
    Joined:
    Nov 19, 2013
    Gender:
    Male
    Occupation:
    Gardener
    Location:
    Tasmania
    Home Page:
    My Bike:
    Spada, VT250F & ZX2R
    Looking good Pete.
     
  8. 2valve

    2valve Well-Known Member

    Messages:
    861
    Likes Received:
    352
    Trophy Points:
    348
    Joined:
    Oct 12, 2016
    Gender:
    Male
    Location:
    Glen Innes Australia
    My Bike:
    1985 Yamaha SRX 250
    Beautiful job. I agree purchasing all of new rubber parts does add up fairly fast. But at'least you've done it correctly and it will last.
     
  9. James Mclaren

    James Mclaren Active Member Contributing Member

    Messages:
    155
    Likes Received:
    93
    Trophy Points:
    128
    Joined:
    Mar 30, 2020
    Gender:
    Male
    Location:
    Ormeau queensland
    My Bike:
    Kawasaki zx2r model A
    Gorgeous job, watching with interest
     
  10. pete05

    pete05 Active Member

    Messages:
    54
    Likes Received:
    26
    Trophy Points:
    88
    Joined:
    Dec 30, 2019
    Gender:
    Male
    Location:
    Australia
    My Bike:
    zxr250c, ninja 1000, fz6r
    Thanks guys, I'm looking for rubber inlet manifold number 4 if anyone can help?
     
  11. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

    Messages:
    5,102
    Likes Received:
    3,472
    Trophy Points:
    1,148
    Joined:
    Dec 23, 2012
    Gender:
    Male
    Location:
    Thailand
    Home Page:
    My Bike:
    Yamaha FZR400 3TJ1, Honda MC22
    Looks like a new one. How did you get that radiator overflow tank to look so clean?
     
  12. pete05

    pete05 Active Member

    Messages:
    54
    Likes Received:
    26
    Trophy Points:
    88
    Joined:
    Dec 30, 2019
    Gender:
    Male
    Location:
    Australia
    My Bike:
    zxr250c, ninja 1000, fz6r
    I used an ultrasonic cleaning tank set a 60deg c with a mix of water and simple green, it came up almost like new.
     
    • Nice Work Nice Work x 1
  13. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

    Messages:
    5,102
    Likes Received:
    3,472
    Trophy Points:
    1,148
    Joined:
    Dec 23, 2012
    Gender:
    Male
    Location:
    Thailand
    Home Page:
    My Bike:
    Yamaha FZR400 3TJ1, Honda MC22
    Thanks Pete I will give it a try.
     
  14. pete05

    pete05 Active Member

    Messages:
    54
    Likes Received:
    26
    Trophy Points:
    88
    Joined:
    Dec 30, 2019
    Gender:
    Male
    Location:
    Australia
    My Bike:
    zxr250c, ninja 1000, fz6r
    So in my search for inlet manifold number 4 on the second hand market, I got offered a "good used" one for $120 on FB and then found a whole head with all four inlets for $80 so I snapped that up today from the local cash and co motorcycle wreckers.
    spare head.jpg

    I have pulled the manifolds off to come across a possible cause of my idle issues, was interesting to see that all four were the same on the spare head and I bet my bike has the same issue.
    It appears with age the rubber seal has shrunk back providing no seal as can be seen with a straight edge across it.
    Anyone else seen this issue?
    inlet rubber.jpg
     
  15. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

    Messages:
    4,730
    Likes Received:
    2,870
    Trophy Points:
    943
    Joined:
    Mar 18, 2014
    Location:
    Sydney NSW
    My Bike:
    FZR250R 3LN6
    The flattened o-ring there is what seals the whole manifold. I'd say those are no good unfortunately, but having a head for spares is always good.

    The manifolds on my C model all had leaks around the vacuum ports, new ones cost about $100 for a set.

    You can see they are numbered #1 #2 #3 #4 for each cylinder, all that really changes is the little index to hold the clamps in the right position so they don't spin when tightening/loosening.

    It's also common for the inside surface not to perfectly match up with the casting on the inlets, so they can be taken to with a dremel etc to get them perfect. Same deal with the trumpets on the airbox side.
     
    • Like Like x 1
  16. pete05

    pete05 Active Member

    Messages:
    54
    Likes Received:
    26
    Trophy Points:
    88
    Joined:
    Dec 30, 2019
    Gender:
    Male
    Location:
    Australia
    My Bike:
    zxr250c, ninja 1000, fz6r
    I'm thinking about making some gaskets to seal it up, I haven't seen a set of new inlet manifolds for $100.
    Interesting about the leaks around the vacuum ports, I will check these ones over.
    I'm going to have to work with what I have for the time being as I just spent my play money on new tyres for my ninja 1000.
     
  17. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

    Messages:
    5,102
    Likes Received:
    3,472
    Trophy Points:
    1,148
    Joined:
    Dec 23, 2012
    Gender:
    Male
    Location:
    Thailand
    Home Page:
    My Bike:
    Yamaha FZR400 3TJ1, Honda MC22
    Now that is interesting. If that is the case then it might be worth making some.
    You can buy new ones from Impex for 16 USD.
    I will put one on my shopping list for medical experiments. Except mine would have a replaceable o-ring groove.
     
    • Like Like x 2
    Last edited: Jun 3, 2020

Share This Page