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Winner OMG Down the rabbit hole I go…

Discussion in 'Kawasaki 250cc In-line 4's' started by BasketCase, Nov 2, 2023.

  1. BasketCase

    BasketCase Member Premium Member

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    Just for a laugh, I thought I’d pull the carbs cos I’m at that stage of the ‘rebuild’… first warning was only 5 screws/bolts holding the airbox… then I removed the airbox… and decided it was time for a coffee… nuff said… the monkeys have been here…

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  2. gregt

    gregt Well-Known Member Premium Member

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    Those broken screws are gonna be fun.
    May i suggest a soak in penetrating oil - 50/50 ATF and Acetone. Followed by gentle heat and the application of a small left-hand drill. Yes, they are available. With luck and a following wind they should come out.
     
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  3. BasketCase

    BasketCase Member Premium Member

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    :headbang::headbang::headbang::headbang:
    I think its wadding or similar stuffed in with the screws because the threads are stripped… that’ll work… not! So my helicoil skills will be tested methinks. I was so pissed off I just bailed and went for a coffee instead… will update tomorrow. :headbang:
     
  4. Murdo

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

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  5. BasketCase

    BasketCase Member Premium Member

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    Thanks Murdo - yup, the screws are snapped off in the carbs. The only good news is that it’s only 4 of them. Will need to take a couple of brave pills before I attempt to remove them. Wish me luck.
     
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  6. BasketCase

    BasketCase Member Premium Member

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    So, I did what was advised by Murdo and GregT. Bought left handed drill bits, soaked the screws for days. You guys rock! All 4 broken screws came out easily!!! I honestly couldn’t believe it. The worst part was centre punching the broken screws. None of the hole threads are damaged so we are good to go. Thank you so much for the advice and encouragement.
    :drinks:


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  7. Murdo

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

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    Another set saved. :thumb_ups:
     
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  8. BasketCase

    BasketCase Member Premium Member

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    Thanks for the tips Doc! Was not looking forward to this task - but fortune favours the brave!
     
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  9. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    Gotta be pleased with that I bet you've got a huge sense of satisfaction and relief 100% success rate
     
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  10. BasketCase

    BasketCase Member Premium Member

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    So relieved!!!
    Was not looking forward to the potential nightmare… but - get good advice, get the right tools, take a brave pill, insert some patience and you’ve got a fighting chance of success. Next mission is replace the fork seals but that’s easy in comparison!
     
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  11. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    When replacing the front wheel and retorquing the 2 pinch bolts , be very careful if theres evidence of scrapes or "damage" to the bottom of the fork .... or if they have been over tightened in the past
    You will see here in my thread what happened with mine ..... and when searching for a replacement I found a few sets for sale that were "cracked" there as well

    https://2fiftycc.com/index.php?thre...odel-stealth-edition.1949/page-24#post-145286


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  12. BasketCase

    BasketCase Member Premium Member

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    :thumb_ups::thumb_ups:O
    Oh Crap! Will check them out tomorrow… knowing my luck they’ll be donald ducked! Thanks for the heads up
     
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  13. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Also on "twin" pinch bolts I tighten them in "increments" to share the load .... and when u have the second to the set torque , you should go back and check the first one again as it will probably have changed.

    When I do the old bikes I usually drop back the recommended torque settings a few Nm .... but thats just me
     
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  14. BasketCase

    BasketCase Member Premium Member

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    Thankfully, the forks look ok - maybe the Kawasaki gods are finally smiling on me for saving this poor basketcase :thumb_ups::thumb_ups:
     
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  15. Why?

    Why? Well-Known Member Premium Member

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    Did the same thing today, picked up another ZXR250 yesterday for something to do and found that some of the air box screws were missing. Managed to remove all the broken bolts except the one that they had tried to remove themselves and mucked it up. Bike is running beautifully.

    IMG_0641.JPG
     
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    Last edited by a moderator: Nov 17, 2023
  16. BasketCase

    BasketCase Member Premium Member

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    Them gaskets look a bit sorry! I guess these ZXR’s are pretty forgiving?
     
  17. Why?

    Why? Well-Known Member Premium Member

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    That was a before shot. Since then broken screws were removed, engine cleaned, some hoses replaced and gaskets made good.
    Pays to always have spare gaskets, o-rings, hoses and carby kits lying around.
     
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  18. BasketCase

    BasketCase Member Premium Member

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    Gotta give us an ‘after’ shot mate!
     
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  19. Why?

    Why? Well-Known Member Premium Member

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    Sorry I only took this photo to as a reference for re assembly, not to show the Carburettors. I tend to take pics every now and then to help if I get stuck when putting the bikes back together. But I did pinch the idea of the left hand drill bits off this post. It was very informative. I do have easy outs but usually use normal drill bits. You learn something every day.
     
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