ZXR250 Kawasaki

Been having some fun with Chris's Kawasaki. The engine started but made sounds most bizarre for this bike. The sound was emanating from around the clutch area.
Pulled the cover and found residue, black in colour but not metal. The strange sound was the cam tension er pressing onto the clutch basket. Chain was stretched and so worn. Removed the cam tension er and found that the chain had chewed up the cam guide which is made of plastic, hence the black residue on the bottom.
Have ordered a new cam chain which should reach me Monday and I can get this bad boy back on the road. Thank god we had a spare motor which I have been able to score some parts off.
I will do the timing and valves whilst she is in this state. Some fresh oil, some green stuff in the radiator, 4 new plugs and she should be ready to ride.
Will keep you posted.
                                                                  Phil

 

Hey Chris

Does this imply that I have to get dirty again. Never mind, hope to get it sorted soon.
                                                                            Phil

 

Hey Phil
You know how it goes, hate to see a grown man cry. All good, hope to be ready to hear this baby run by Tuesday.
However, it is subject to change if this rain doesn't stop.
                                                          Phil

 

What is it I like about kawasaki zxr250............. NOTHING!!!!!
This bike has been driving me crazzy, one thing after another. A week of frustration and set back after set back, it's like it wants me to fail.
Not in my wildest dreams did I think this would be so challenging, but never say die and day after day I eliminated bit by bit.
Fitting a head and gasket and new cam chain isn't that difficult, or so I thought.
By mid week had it ready to start, but alas that didn't happen. Check compression, no reading on 3 of the 4 pots, pull the head back off.
Poured fuel down the back of the inlet and exhaust ports and watched fuel seep out of every valve, not good? Whilst pouring the fuel out a chim bucket falls out, and you guessed it, no chim. Grab a magnet and check the rest, not one single chim to be found. Becomes very evident now, why I had nil compression.
So Friday morning removed all valves and cleaned each one on the wire wheel, also did the seats and fitted chims. Performed same test with fuel and this time not a single drop to be found, happier camper.
Head is now fitted to the engine and torqued to specification. Monday will fit cams and with a little luck will fire this  BAD BOY up, and Chris can have his bike back.
Stay tuned for another episode of "WHAT I LIKE ABOUT ZXR250"
                                                                    PHIL

 

Hey Desmo
Couldn't agree with you more, bloody big job.
                                                            Phil

 

Hey AJ
Settle down, I can only repair, video ain't my forte. Bloody nice to hear it run with good compression.
                                                                  Phil

 

The day started nicely, the weather was warm, good coffee and just a few bits to fasten and the zxr250 should be a goeeeeeerrrrr!!!!!
Wrong, as I was testing the cam movement, the chain came off.
Take 2  and this time it came together well, who said I don't like Mondays!!!
Next issue, the clutch simply wasn't working correctly? Why me, pulled it out and checked it and put it back together, adjusted the play and Presto, the clutch works.
Changed the oil, new filter and connected the radiator and filled with fluids and she was getting close. Battery was a little flat, used the jump pack and by god she started, sounded good to me. Couldn't help myself, rang Chris at work and put the phone so he could hear his baby running again, think he was happy.
Tomorrow morning give her the once over, re attach the panels and a couple of loose wires and this bad boy should be ready for the open road, thank goodness.
                                                                  Phil

 

Well Folks, as they say, "That's me done". The Kawasaki zxr250 is finished and looks and sounds good. Very slight oil leak coming from the clutch cover housing, sadly I didn't have a gasket. Chris is arranging that. Gasket gooo will only do so much.
She has tested me every inch of the way, glad we finally got on top.

On to the next project, I'm certain Chris has something else in mind.

                                                    Phil