My ZXR250A Project Log

Looking for ZXR250a Carb Gaskets + Advice

Hi Guys,
Slowly... ever so slowly fixing all the problems on my ZXR250A.
Can't say it's not half expected from a 24 year old bike.

So next on my list is the problem of Carb Gaskets (top end where the air box intakes mate) all 4 of them are missing.

I've looked online, Ebay, Jap-rider and other stores. Can't even find references to them let alone any for sale.

Does anyone know where I can find them? Or have any for sale?
Also as the bike has previously been running before I bought it and still runs (long story there) does it damage or effect the engine without the gaskets?

Also I have a leaky tank where the bottom tank support connects to the tank. Any sealant products I can use that are safe for this? Or am I going to have to take it to a pro?

I have a dozen other problems, I'll start a project log post in ZXR250 section soon might help anyone with similar problems.

 

Thank you very much for the help
I will try the local Kawa dealer but I have a feeling the reply will be the same as the other parts I have tried for... "What's a ZXR250" haha

 

Thanks Kiffsta,

Yea I found out about the Balius. I also have had part numbers for all the things I've looked for up till now. I think honestly Kawwa want's nothing to do with the parts , like you said GreyImport I didn't buy their bike.

I've had to source parts from the UK mostly so far. Only gotten basic stuff in AUS.

Finally got round to cleaning the carbies tonight, BOY were they grimy. Need to add 4x float needles to the list now.

 

You're a champ Kiffsta. I got a whole bunch of Misc nuts, bolts and fixing parts from an Ebay store from UK. They were cheap as chips because of exchange and I was in no rush. Took three weeks to get em by mail. The rest of the stuff I have gotten from http://www.motorcyclespareswarehouse.com.au and local shops.
Going well so far. Fingers crossed.

 

Finished pulling apart, cleaning and reassembling the carbs this-evening. +1 to a very useful guide from Kiffsta which was a very good reference as I have not worked with ones like this before.

Carbies had years of grime and deposits built up in ever nook and cranny. Went through it with a fine eye and is looking much better now. Had to replace all of the float valve needles and seats as the old ones were not even holding the floats up and had seized from a build-up of gunk.
I purchased them from Motorcycle spares warehouse, my order was placed Sunday night, shipped Monday and arrived in my mailbox this morning, very impressed. (Link below)
Replaced them and am now getting a consistent 13-14mm on floats.

Just need to get a carb balance, throw it back together and see how she runs on the cleaned carbs and new iridium plugs.
EXCITED!

Link to Float Valve Needles and Seats- (http://www.motorcyclespareswarehouse.com.au/products/khv-24l24-float-valve-needle-and-seat)

 

So bit of an update with some good and bad news.
She's all back together now, tank sealant worked the treat so far. Engine is now getting clean fuel.
However I am puzzled by a few things.
I changed the Air/fuel mix back to stock when I was cleaning the carbies as they were out by about a turn.
I booted her up for the first time since clean last night, started up first go after about a second with the choke, a smign of throttle.
I was surprised when it fell off the choke after about twenty seconds then proceeded to idle completely smoothly?
Usually I have to keep the choke on for at least two minutes.
At first it was blowing a small amount of white smoke but after sixty seconds the smoke goes away and it's clean as.
Took it down the road for one run once it had warmed up. Noticed that the engines cools down on the run on the temp gauge. It also backfired once or twice on the downrun.
Is this a mixture problem? May be running too rich? Idea's anyone?

I am going to do an oil change today for safe measure as well.

 

Well it never backfired before I did the work to the bike. The muffler and headers seem fine to my eyes.
The other details I can give after a little further testing include.

A drop in power but much more throttle response than previous. Also the engine sounds much healthier, less metallic rattle and a deeper sound out of the engine.
The engine seems to choke a little after going for a longer run down the road. This co-en-sides with the drop in engine temperature. I thought it could be the thermostat is stuck open, but this problem wasn't occurring before.
I am currently using 95 Octane from the Local BP. Previous I had 95 from the local Caltex.
I did just change the oil about 10 minutes ago for safe measure. It came out far too runny and almost diluted with something. So fresh oil/filter is in now.

 

Yep everything in the fuel side of things between the tank and the exit to the carby have been replaced or reconditioned.
Yep plugs are in the right order but I am going to have to go back and have another look at them.
Thanks to the help of an extra set of ears we think it's not running on all 4, and a hand on the extractors semi-confirmed this. I assume this would explain the backfires and loss of power, maybe its 2 down not 1 anymore.

Unfortunately I am getting to the limit of what the internet and my level of expertise can handle. If i can't get it running right I am getting closer and closer to the dreaded possibility of an engine rebuild.

 

Well that's good to hear Chris I don't want to go into the engine, I may have to take you up on that offer. I borrowed one from a mate at work but it was a difficult fit so couldn't get it into the holes well and get a good seal.
It has to be something obvious I am missing that's messing with the way it's running.
At some point there was a good reason it was rolled into the shed with only 36k on the clock. If I can fix whatever that problem is, should be on the right track.

 

Thanks for the advice guys

I'll give that all a try and let you know how it goes. It's difficult yo diagnose the exact cylinders miss-firing with just my hands. At first I thought it was three, then the next time I started it three was burning and two was only warm, and then back the other way again.

It's all very frustrating, but in an annoying, time consuming way also very fun!