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ZXR250: The loose change project

Discussion in 'Your 250cc Projects' started by jazzhunt, May 27, 2015.

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  1. Murdo

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

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    That may just be the mark from the former when they bent the metal.
     
    Murdo, May 29, 2015
    #21
  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    • Like Like x 1
    GreyImport, May 29, 2015
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  3. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    Getting the airbox in and out is quite the struggle, there is a trick you learn over time but start it at an angle of about 50 degrees and sort of twist it in there, then you need to push forward and down to get the breather onto the outlet.

    All whilst not disturbing the carb to airbox seals!
     
    Th3_Huntsman, May 29, 2015
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  4. jazzhunt

    jazzhunt Well-Known Member Premium Member

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    My airbox is very slightly different from that diagram (a couple of plastic pieces not shown) but, on the other hand, it is identical to a photo @kiffsta put on this thread http://2fiftycc.com/index.php?threads/fuel-leak-zxr250c.1468/ so I'm wondering if PO sourced a C model airbox.
    Sigh, which makes me wonder if that 'spare' motor was the original and I now have a C motor in an A-frame?? Time to go pull some plastic off, methinks :)
     
    jazzhunt, May 29, 2015
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  5. kiffsta

    kiffsta Senior Member

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    Look at your engine number , it will tell you if it's an a or c
     
    kiffsta, May 30, 2015
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  6. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Cakes?
    Rec_Oven.jpg
     
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    Last edited: Aug 16, 2015
    maelstrom, May 30, 2015
    #26
  7. jazzhunt

    jazzhunt Well-Known Member Premium Member

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    LOL, @maelstrom :) I recently cooked a rectifier on an outboard and ending up replacing it with a modern alternative instead of the factory one so I won't be at all surprised to find this one cooked too :)
    Thanks, @kiffsta , checked the engine number and it is an A motor, which is a good start. I'd still like to compare an A and C airbox side by side but there is no rush. my local bike wrecker wants $70 for an A airbox, which seems a little high to me, given it has no filter but I have much to do before I get there anyway.
    Like, for example, replacing the rocker cover and, hmmm, maybe finding an actual gasket? Jeez, dude, really? You couldn't fork out for an actual gasket?

    [​IMG]
     
    jazzhunt, May 30, 2015
    #27
  8. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Do u have a rocker cover from the spare motor?

    Remove the cover carefully .... there may just be a gasket there under the silicone fix it job .... it may have just been leaking because of the damage and the fixing bolts not tensioned down correctly.

    Seems new rocker gaskets are a little hard to find , and not cheap.... Ive been looking also.

    http://www.ebay.com.au/itm/KAWASAKI...737?pt=LH_DefaultDomain_3&hash=item2ec876dd61
     
    GreyImport, May 30, 2015
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  9. jazzhunt

    jazzhunt Well-Known Member Premium Member

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    Ah, that might explain it @GreyImport . No, the spare motor came without a rocker cover.
    And, no, on the other side of the motor one bit of the silicone has 'blown out' so I can tell there is no gasket hiding in the goo :)
    So, I'll start looking for a gasket and enjoy the fact that I don't need it in a hurry...
    Thanks for the heads-up!
     
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    jazzhunt, May 30, 2015
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  10. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Well what can you say about that craftsmanship? Better do a thorough check once you do get the cover off. Silicone blocks up engine oilways real quick.
     
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    maelstrom, May 30, 2015
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  11. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    maelstrom, May 30, 2015
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  12. jazzhunt

    jazzhunt Well-Known Member Premium Member

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    Thanks @maelstrom , I'll get on to that.
    Given the of the PO's work, I've decided that the only way I can be really confident is to rebuild everything from the ground up. I can't handle worrying about what else he may have done so it's the only way.
    And, hey, I said this was going to be a long project :)
     
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    jazzhunt, May 30, 2015
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  13. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Agree 100% Jazz. Then you know you have a good bike and most of it is elbow grease.
    About the rocker cover gasket, the amount of compression is determined by the rubber seals that fit under the shoulder bolts (you can imagine if you removed them the cover would just flop about), so you should replace those parts at the same time.
    I vaguely recall someone mentioning that if the cam chain was worn it would hit the inside of the cover on the 250. In any case @Linkin did a very good thread on replacing a cam chain without splitting the motor. Should go in the tech tips section I think.
     
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    maelstrom, May 30, 2015
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  14. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    Judging by that picture it already has and likely wore a hole in the rocker cover.... Just looks like a patch job there to me is all
     
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    Th3_Huntsman, May 30, 2015
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  15. kiffsta

    kiffsta Senior Member

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    kiffsta, May 30, 2015
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  16. jazzhunt

    jazzhunt Well-Known Member Premium Member

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    Thanks again @maelstrom , I've got one ordered now. I won't be needing it for a while but I suspect this may be one of those items you should grab when you get the chance:)
    I'm not in any shape to do very much today, after last night's shenanigans, but I did get enough cash-in-cards to replenish the project funds enough to cover a couple of parts :)
    [​IMG]
     
    jazzhunt, May 31, 2015
    #36
  17. jazzhunt

    jazzhunt Well-Known Member Premium Member

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    So, after months of not even visiting the shed to to health issues and assorted crap, I finally got to take a few things off the ZXR and hit it with the Gurni to see what was buried under decades of neglect.
    Meh, it's nothing fabulous but I've seen worse :)
    Maybe by Christmas I'll actually do something to it :)
    [​IMG]
    [​IMG]
     
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    jazzhunt, Aug 16, 2015
    #37
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