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Old April 6th, 2017, 03:14 AM   #1
Linkin
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Back again with a ZXR250C

My latest ride which I will keep until I get my full license next year. Another little 250cc inline 4 pot screamer, this one redlines at 19,000rpm.

There are A/B/C/D models for the ZXR250. A models are 1988-1991 and are 45HP motors. B models are a rare race spec version with different CDI, cams, carbs and a closer ratio box from 1st to 3rd gear. C models are 1993-2004, have 40HP and were made in both Japan and Malaysia. D model is just a C model with the B model race-spec bits. Due to Japanese law, you get funny things like "speed lights" that light up at 80KM/h (easy to fix, remove the bulb), 40HP/32KW restrictions from 1993 onwards, and some bikes have electronic/CDI limitation to 180KM/h.

Mine is a 1999 built in Malaysia as it has safety stickers in Malaysian and has made in Malaysia stamped all over its bits and pieces. I've also had it up to 200KM/h indicated on the speedo while at the track so I don't think its restricted, apart from being a 40HP motor.

Pictures of as it was when I got it. It needed a service including valve shim adjustment which I gone done at work, since I work for a motorcycle shop now I also got the timing chain and notoriously crap tensioner done (used a GPX250 one)







The carbs needed work (which I did at home) as there was a flat spot between 6k-8k RPM. The carbs have vacuum lines/vacuum fuel tap and the seals between each carb body are known to go brittle and fail. I replaced them, but I had to fight overtightened JIS screws (aka Japanesive phillips, but its not a phillips. If the screw head has a dimple, it's JIS and you need special JIS screwdrivers or you'll make a mess of the heads) to get the carbs apart.









After that I got an aftermarket exhaust, the stock one makes an incredibly dull wheezing, aftermarket much better



Link to original page on YouTube.

The plastic tubes on the tank are for the voltage reg/rec, which lives under the fuel tank. Mine had deteriorated so I got new ones, along with a new reg/rec



New rear tyre put on & balanced at work... fun fact... its an 18" rear rim, which limits tyre choice... I can potentially use a ZXR400 rim or ZR250 Balius rim which are both 17"





And just recently, some orange rim tape and ninja stickers to match the decals on the tank

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Old April 6th, 2017, 05:55 AM   #2
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nice one, wish we could get them here in the states.
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Old April 6th, 2017, 07:07 AM   #3
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Yes, very cool bike. I wonder what was done to restrict the HP to 40. Sometimes it's something very simple, as opposed to different cams, for example.
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Old April 7th, 2017, 12:31 AM   #4
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Quote:
Originally Posted by Triple Jim View Post
Yes, very cool bike. I wonder what was done to restrict the HP to 40. Sometimes it's something very simple, as opposed to different cams, for example.
Almost all of the 250cc inline 4's were restricted via different cams and different rev limits for 1993. For example the late FZR250R's only rev to 16,500 instead of 18,500. But that said the 40HP bikes are still great to ride and a bit less peaky, they make a tad more torque down low

On the Yamahas you can run an earlier cylinder head and cdi box to get 45HP back, as the bottom end is the same, I've done it.

On the Hondas you wire in a resistor to disable the 180KM/h limiter, and you can probably run an earlier cylinder head and cdi box as well.

The ZXR's however have different bore & stroke from the A to C models so I don't think it's possible to run an earlier cylinder head.

But really if you need more power you either spend a fortune on performance mods like bigger valves, port & polish, bigger bore/stroking etc or just buy a bigger bike.

I'd love to get an older kwaka 600 motor/loom and see if I can stuff it in the 250's frame
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Old April 7th, 2017, 07:05 AM   #5
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Thanks, interesting information.

One of the guys here put a Banshee engine in his 250. It's quite an interesting bike.
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Old September 18th, 2017, 03:45 AM   #6
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Haven't been on here in a while. Lost my license for 6 months back in May for having too much fun and getting caught doing it. The irony is that I've had bigger more powerful bikes before the nanny state deems you worthy, yet lost my license on a bike I'm actually licensed for.

The 'prison colony' mentality is alive and well.


In any case, I got the new tyre scrubbed in before that happened.




Paid a lot of money for this plate...




Since then I stashed the bike at work and have been doing work on it during the weekends.

When syncing the carbs, I sprayed brake cleaner at the vacuum lines and boots... all stuffed...




New boots and trimmed the ends of the vac lines




Got myself some serious tools sorted for work






Signs of reg/rect problems...




New Shindengen SH847 mosfet / non-shunting reg/rec. Too bad my stator was also shorted out and is off being rewound




I have also ditched the old style coils, leads and spark plug caps for Ninja 300 coil on plug units. Still running a wasted spark setup until I figure out a programmable ignition of some sort. Long term project.







That's it for that bike... but I bought a second one!















Problems... it has an oil leak from the front sprocket. Overtightened chain I suspect. In any case it's an engine out and apart to fix it. I bought a 2nd hand spare motor and am slowly doing the required servicing on it.




Cam cover off and cams out. Bit of gouging on the cover, caused by the ****** cam chain tensioners. To be replaced with a new GPX250 unit on the way.






Clearances... way too tight... though this motor was sold to me as running by someone I know and trust, so hopefully the new shims I put in will make it run better once the motors are swapped out.

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Old September 18th, 2017, 11:09 AM   #7
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Your tool box is beautiful! Glad you'll have your bikes back on the road soon.
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Old October 21st, 2017, 01:18 AM   #8
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New vs old stator. Also had a short in the loom that was draining the battery. Bypassed loom for the new stator. Now headlight is out, need to wire it into ignition switch with new relay and fuse















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Old December 19th, 2017, 04:26 AM   #9
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Back on the road with repairs done and enjoying riding again



My mate's CBR250RR



At the pub with more mates

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Old December 19th, 2017, 05:48 AM   #10
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Quote:
Originally Posted by Linkin View Post
My latest ride which I will keep until I get my full license next year. Another little 250cc inline 4 pot screamer, this one redlines at 19,000rpm.

There are A/B/C/D models for the ZXR250. A models are 1988-1991 and are 45HP motors. B models are a rare race spec version with different CDI, cams, carbs and a closer ratio box from 1st to 3rd gear. C models are 1993-2004, have 40HP and were made in both Japan and Malaysia. D model is just a C model with the B model race-spec bits. Due to Japanese law, you get funny things like "speed lights" that light up at 80KM/h (easy to fix, remove the bulb), 40HP/32KW restrictions from 1993 onwards, and some bikes have electronic/CDI limitation to 180KM/h.

Mine is a 1999 built in Malaysia as it has safety stickers in Malaysian and has made in Malaysia stamped all over its bits and pieces. I've also had it up to 200KM/h indicated on the speedo while at the track so I don't think its restricted, apart from being a 40HP motor.

Pictures of as it was when I got it. It needed a service including valve shim adjustment which I gone done at work, since I work for a motorcycle shop now I also got the timing chain and notoriously crap tensioner done (used a GPX250 one)







The carbs needed work (which I did at home) as there was a flat spot between 6k-8k RPM. The carbs have vacuum lines/vacuum fuel tap and the seals between each carb body are known to go brittle and fail. I replaced them, but I had to fight overtightened JIS screws (aka Japanesive phillips, but its not a phillips. If the screw head has a dimple, it's JIS and you need special JIS screwdrivers or you'll make a mess of the heads) to get the carbs apart.









After that I got an aftermarket exhaust, the stock one makes an incredibly dull wheezing, aftermarket much better



Link to original page on YouTube.

The plastic tubes on the tank are for the voltage reg/rec, which lives under the fuel tank. Mine had deteriorated so I got new ones, along with a new reg/rec



New rear tyre put on & balanced at work... fun fact... its an 18" rear rim, which limits tyre choice... I can potentially use a ZXR400 rim or ZR250 Balius rim which are both 17"





And just recently, some orange rim tape and ninja stickers to match the decals on the tank

DANG! I want one!

Bill
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Old December 19th, 2017, 06:58 PM   #11
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Nice

On another note need more zxr400 in australia
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Old December 19th, 2017, 07:34 PM   #12
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Old December 19th, 2017, 08:28 PM   #13
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Pretty bike, I'd love to give an inline 4, 250cc a go.
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Old January 4th, 2018, 01:00 AM   #14
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I finally got out and did some riding on new years eve... roads deserted and no cops around









And I thought this graffiti where I parked my bike today was cool, so I snapped a pic

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Old January 4th, 2018, 11:46 AM   #15
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Lovely!
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Old May 9th, 2018, 04:53 AM   #16
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New rear disc and pads, replaced missing anti rattle spring






Got a bubble screen fitted. I can see my instruments now



Went Riding







Bonus: Honda CBR250RR




More mechanical stuff... forks seals & steering head bearings












Did my first track day a while back - hooked




Had the tank and airbox off to replace the crank breather vent



Pulled the carbs and found a diaphragm cap screw missing - it was sitting between the intake manifolds... fixed that.

Also modified the slides, drilled an additional 2.5mm hole next to the existing one. Improves throttle response between idle - 6k rpm. Supposed to use heavier diaphragm springs as per the ZXR400 race prep manual but I haven't got any yet. Haven't had any issues.

Still chasing the 7k rpm flat spot, all air leaks have been fixed and I have tuned and balanced the bike... only things remaining are the airbox itself and the fresh air vacuum valve. There is no secondary air system and I wouldn't touch it anyway.
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Old May 9th, 2018, 06:59 AM   #17
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Quote:
Originally Posted by Linkin View Post
New rear disc and pads, replaced missing anti rattle spring






Got a bubble screen fitted. I can see my instruments now



Went Riding







Bonus: Honda CBR250RR




More mechanical stuff... forks seals & steering head bearings












Did my first track day a while back - hooked




Had the tank and airbox off to replace the crank breather vent



Pulled the carbs and found a diaphragm cap screw missing - it was sitting between the intake manifolds... fixed that.

Also modified the slides, drilled an additional 2.5mm hole next to the existing one. Improves throttle response between idle - 6k rpm. Supposed to use heavier diaphragm springs as per the ZXR400 race prep manual but I haven't got any yet. Haven't had any issues.

Still chasing the 7k rpm flat spot, all air leaks have been fixed and I have tuned and balanced the bike... only things remaining are the airbox itself and the fresh air vacuum valve. There is no secondary air system and I wouldn't touch it anyway.
Simply eloquent! You need to take this sport of motorcycling a-lot more seriously.

Bill
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Old May 10th, 2018, 08:44 AM   #18
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Very cool bike , Wish I could get one here ,
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Old June 3rd, 2018, 01:58 AM   #19
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Been off riding, wore out the tyres and the chain and sprockets went crusty, so time for some more bike love. Adjusted the steering head for the final time, cleaned air filter, etc















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Old June 3rd, 2018, 03:58 AM   #20
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awesome.
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Old June 3rd, 2018, 09:23 AM   #21
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Looking good!
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Old June 5th, 2018, 09:04 PM   #22
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Man, that bike is gorgeous! I love/hate every time we hear of a new thread where some lucky person lands one of these. No ZRX250 love over here stateside.
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Old July 7th, 2018, 02:13 AM   #23
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Went out and scrubbed in the new tyres a while ago




Love this shot. Throttle pinned and the rear squatted down





And just before that





My favourite two shots







And was busy avoiding these guys...





Then the bike turned evil on me


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Old July 7th, 2018, 02:28 AM   #24
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It's tax time in Australia, so got my return sorted and refund in my account.

I had enough to cover for some parts I've been meaning to order in preparation for a minor engine refresh

So, the list is as follows.

Rings, wrist pins, circlips and gaskets
Clutch basket
Manual CCT
New slip on exhaust
New dash bulbs

Plan to do the clutch first, then see if I can pull the head and barrels off without dropping the engine. Some minor head work / porting may be on the table. Going with standard size rings for now, but if an overbore is required I will do it.

I've already replaced the standard lead acid battery (about 3kg) with an ultralite lithium weighing in at a whopping 700 grams... when the bike weighs 141kg it is a big weight saving.
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Old November 24th, 2018, 05:01 AM   #25
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Been a while, done a whole heap of stuff including rebuilding the top end, so I'll just dump the photos




















Dyno run without a tune, has since been tuned and am going back to the dyno as soon as I can.



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Old November 24th, 2018, 08:01 AM   #26
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Great looking work ,
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Old November 24th, 2018, 05:27 PM   #27
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