February 14th, 2015, 07:56 PM | #1 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
FZR250R 3LN3 Restoration
Thought I'd make a separate thread for this.
Bike arrived 11am today. This scared me for a bit, but it was just me spilling fuel while filling Decent spares list plus air filter which is unobtanium/expensive New battery, some fuel, and a minute or two of cranking and she came to life. Was a little dry in the oil department, definitely sounded like a lawnmower until I topped up the oil. Has a leaking coolant hose, engine is a bit tappy. Have a new cam chain & tensioner in the box of crap that came with it. A full set of spare fairings which is always nice. |
1 out of 1 members found this post helpful. |
February 15th, 2015, 11:04 AM | #2 |
The Corner Whisperer
Name: Chris (aka Reactor)
Location: Northern KY
Join Date: May 2011 Motorcycle(s): 2010 250 (track), 1992 250, 2006 R6 (street/track), 2008 R6 (track) Posts: Too much.
MOTY 2015, MOTM - Nov '12, Nov '13
|
__________________________________________________
Goal: Shake A Million Hands | Look through the corners | Track Day Prep | Closest track? | The Mid-Ohio School |
|
February 15th, 2015, 12:54 PM | #4 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
Yeah it's on the list.
Oh and by the way, the frame is a 3LN3 frame, the engine is a 3LN7 according to the serial... they sold maybe ~1000 of them only in Japan. Other bike is a 3LN6 with only 9000 units produced |
1 out of 1 members found this post helpful. |
February 15th, 2015, 01:28 PM | #5 |
ninjette.org member
Name: Tim
Location: NJ
Join Date: Sep 2013 Motorcycle(s): 2006 Ninja 250 Posts: 47
|
What year is that? The looks of it are definitely ahead of its time.
|
|
February 15th, 2015, 04:49 PM | #6 |
in your machine
Name: Scott
Location: Summer Shade, Ky.
Join Date: Oct 2014 Motorcycle(s): 98 Ninja 250/F12 aka ZX-2R "SERENITY", 91 Ninja 500/A5 aka ZX-5R "Phoenix", 84 Honda GL1200A "SIREN" Posts: A lot.
Blog Entries: 25
MOTM - Jun '17, May '16, Mar '15
|
__________________________________________________
violente et ignorantia ZX-2R BLOG Twitter and Instagram = Ghostt_Scott I'm not here to change your mind, just to inform. |
|
February 15th, 2015, 11:31 PM | #7 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
|
|
February 16th, 2015, 01:50 AM | #8 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
Today's progress
Stripped fairings front & rear Identified fuel leak location Relocated/tightened clamp on coolant hose/pipe - no longer hissing/leaking Other finds: Headlight switch block has been modified to be always-on Seat doesn't fit properly. Battery too tall Checked the EXUP and it's actually working with the new battery... though it does sound a bit sad. I'll try some cable lube
Link to original page on YouTube. |
|
February 17th, 2015, 05:43 AM | #9 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
Okay... Got the oil filter in the mail today, so I did an oil & coolant change
Old oil was not runny, but it's a bit dark. Mounted choke assembly I retrieved only ~750ml's of coolant from the bike, most of that was from the overflow bottle. Very little came out of the radiator. I almost used all the coolant filling up the radiator, and also filled the overflow bottle half way. I did drain the radiator first, it didn't suck anything from the overflow bottle, which is worrying. Not a big issue now that the radiator is full. I also discovered my side stand switch is not bolted on, it's just sitting there held on by grime. It fell out of place during the oil change The engine is still making godawful noise... also doubt the exhaust will pass a blueslip so going to have to use the 3LN6 one. Engine sounds bloody awful... I've had a few suggestions to check the bolts on the headers so I will do that. |
1 out of 1 members found this post helpful. |
February 17th, 2015, 11:53 AM | #10 | |
-
Name: -
Location: -
Join Date: May 2009 Motorcycle(s): - Posts: A lot.
|
Quote:
|
|
|
February 17th, 2015, 12:17 PM | #11 |
Fighting Texas Aggie '05
Name: Neil
Location: Hutto, TX
Join Date: Feb 2009 Motorcycle(s): '07 ZX6R, '08 Versys, '09 250R Track, '93 F2/F3 Track Posts: A lot.
|
Awesomeness
__________________________________________________
Keep it rubber side down and enjoy the ride Get healthy - Get Fit - Change Your Life Click Here Or PM Me To Find More - Advocare |
|
February 17th, 2015, 12:37 PM | #12 |
Inline 4!!!
Name: Danny
Location: MA
Join Date: May 2014 Motorcycle(s): 2008 CBR600rr, 1987 KLR 250 Posts: A lot.
|
God dang I want an inline 4 250! Why don't they make them anymore!! *Subbed! You mind telling me what you paid?
__________________________________________________
Be careful. Remember you are invisible |
|
February 17th, 2015, 02:22 PM | #13 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
|
|
February 17th, 2015, 03:22 PM | #14 |
Inline 4!!!
Name: Danny
Location: MA
Join Date: May 2014 Motorcycle(s): 2008 CBR600rr, 1987 KLR 250 Posts: A lot.
|
Always haggle. However, that's still $1,172 USD which is still a great deal. I'd pay that for that bike.
__________________________________________________
Be careful. Remember you are invisible |
|
February 18th, 2015, 12:32 AM | #15 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
I tightened up the headers. Lawnmower sound = dead. Bike is a lot quieter. Still rattly while idling. Rode it to get fuel, it's smooth. Handlebars need adjustment but the bike tracks straight. No odd vibrations or noises, and the rattle disappears above 6k rpm or so. Exhaust still sounds crappy. Probably right about missing on one cylinder.
The mechanic should have an easy time. To do the valve clearances they need to take off the cams and chain/tensioner, I have the rocker gasket and the head gasket so no issues with that. Plug change should be simple for them. Idle is still high so I'll have them look at that. The best bit? It didn't flood, and there are no flat spots. Guess who doesn't need to mess with carbs? |
|
February 18th, 2015, 07:55 AM | #16 |
Fighting Texas Aggie '05
Name: Neil
Location: Hutto, TX
Join Date: Feb 2009 Motorcycle(s): '07 ZX6R, '08 Versys, '09 250R Track, '93 F2/F3 Track Posts: A lot.
|
^^ good deal, man I want to ride one of those
__________________________________________________
Keep it rubber side down and enjoy the ride Get healthy - Get Fit - Change Your Life Click Here Or PM Me To Find More - Advocare |
|
February 21st, 2015, 09:19 PM | #17 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
I picked up a new instrument cluster as well
|
|
February 26th, 2015, 12:40 AM | #18 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
Today's game, odd one out! F%&$#!!!!
|
|
February 28th, 2015, 12:07 AM | #19 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
Changed the cam chain tensioner, but the bastard is still noisy. Changing the chain is next on the to do list
Old tensioner has bent springs |
|
March 1st, 2015, 07:44 PM | #20 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
JB Weld to the rescue Registered the bike and rode to work. Last on the to-do list is cam chain and valve clearances. Cam chain is a big job and requires the cases to be split Last futzed with by Linkin; March 1st, 2015 at 08:51 PM. |
|
March 1st, 2015, 08:03 PM | #21 |
ninjette.org sage
Name: Aaron
Location: Winder, GA
Join Date: Jun 2012 Motorcycle(s): 2013 Ninja 300 Posts: 718
|
JB Weld is the business.
__________________________________________________
DISCLAIMER: I generally have no idea what I'm talking about. |
1 out of 1 members found this post helpful. |
March 1st, 2015, 11:20 PM | #23 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
|
|
March 16th, 2015, 03:45 AM | #24 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
Cam Chain 101 - Yamaha FZR250R
Plenty of access with the carbs, airbox, radiator and rubber engine cover gone. Had no issues there This is what your timing marks should look like. The T is under the stator cover. The dimples are on the cams and cam guides. When these all line up, you are at TDC for Cyl #1 on the compression stroke - no valves open Your cam chain should have 6 links between the cam sprocket teeth that are facing "upward" - in the sense of where the engine is pointing. EMGO chain breaker kit cam in very handy. Would not have been able to do this job without it. Pin out of the new chain Wiring up the old chain to keep it in place. Cam chain tensioner is out at this stage (not that it mattered, because the chain was rooted. Stretched by 5mm) Old chain apart After this we removed the cam guides, cams, joined the new chain on & fed the old one out, got the crank to the T mark, replaced cams, & joined the chain This is what we ended up using to hold the pin in place. Zip tie on the pin, which ended up on the rod pushing the pin in. New chain in but slack, still has 6 links between the cam sprocket pointing upwards (in relation to engine) - tensioner out Testing after the job is done. Obviously rotated the engine manually beforehand to ensure nothing was binding, and idled it for a while.
Link to original page on YouTube. |
1 out of 1 members found this post helpful. |
March 18th, 2015, 11:04 PM | #25 |
ninjette.org dude
Name: 1 guess :-)
Location: SF Bay Area
Join Date: Jun 2008 Motorcycle(s): '13 Ninja 300 (white, the fastest color!), '13 R1200RT, '14 CRF250L, '12 TT-R125LE Posts: Too much.
Blog Entries: 7
|
__________________________________________________
Montgomery Street Motorcycle Club / cal24.com / crf250l.org / ninjette.org ninjette.org Terms of Service Shopping for motorcycle parts or equipment? Come here first. The friendliest Ninja 250R/300/400 forum on the internet! (especially Unregistered) |
|
March 20th, 2015, 01:12 AM | #26 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
Moar pics
Also replaced the needles and emulsion tubes in my carbs. This has halved my fuel usage. I did 106.2KM and used 4.83L - that's 21.987KM/L or 51.74 mi/gal (MPG) |
|
March 20th, 2015, 03:32 AM | #28 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
I want to visit the US one day and find some good shooting ranges to have a go of some select fire rifles / machine guns!
Firearms laws here in oz are a bit ****. My license allows me to purchase/own rimfire/centrefire bolt action, lever action, and pump action rifles. But nothing that's a "military design" so no AR type rifles. Don't even ask about semi autos or pump action shotguns, or select fire rifles. It's too much money and effort to become licensed, as the government prefers. It's a privilege and not a right here, privileges can be revoked at any time... Handgun licenses are massive pain in the ass as well |
|
March 23rd, 2015, 06:29 AM | #29 |
Fighting Texas Aggie '05
Name: Neil
Location: Hutto, TX
Join Date: Feb 2009 Motorcycle(s): '07 ZX6R, '08 Versys, '09 250R Track, '93 F2/F3 Track Posts: A lot.
|
Man this thread keeps me wishing I could get my hands on one of these old 1/4 liter sport bikes.
__________________________________________________
Keep it rubber side down and enjoy the ride Get healthy - Get Fit - Change Your Life Click Here Or PM Me To Find More - Advocare |
|
March 23rd, 2015, 01:40 PM | #30 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
By the way, this is me at eastern creek raceway in Sydney
|
|
March 28th, 2015, 03:55 PM | #31 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
Alright Ninjetters... got a problem: Boiling coolant out the overflow bottle/escape tube.
Testing with the bike on the stand, high revs = more bubbles/boiling. Cooling system was flushed 3 weeks ago Thermostat was replaced Checked water pump / impeller - working ok In my mind that only leaves a few things. Cracked/warped head or failed head gasket (not catastrophic failure though) Here's the thing though, the bike runs fine, not low on power at all, and it does not overheat... not until the coolant level gets low from the boiling. Fill it up and its fine again. Opinions? |
|
March 28th, 2015, 06:38 PM | #32 |
Rev Limiter
Name: Jay
Location: WI
Join Date: Jul 2013 Motorcycle(s): '06 SV650n, '00 Derbi GPR, '64 CA77 Dream 305, '70 CL450 Scrambler, numerous dirt bikes Posts: A lot.
MOTM - Jun '18, Oct '16
|
Radiator cap not sealing or holding adequate pressure would be the first thing I would check.
|
|
March 28th, 2015, 07:11 PM | #33 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
|
|
March 28th, 2015, 08:45 PM | #34 |
Rev Limiter
Name: Jay
Location: WI
Join Date: Jul 2013 Motorcycle(s): '06 SV650n, '00 Derbi GPR, '64 CA77 Dream 305, '70 CL450 Scrambler, numerous dirt bikes Posts: A lot.
MOTM - Jun '18, Oct '16
|
You are using coolant and water, not just straight water, right?
|
|
March 28th, 2015, 09:29 PM | #35 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
Straight water no. Used premix and added some water friday night
|
|
March 28th, 2015, 10:44 PM | #36 |
wat
Name: wat
Location: tustin/long beach
Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much.
Blog Entries: 5
MOTM - Oct '12, Feb '14
|
could be the radiator is clogged, or the cooling system has bubbles in it? maybe the water pump has damage and isn't pumping adequately. when it was flushed, did it flow well through the engine? sometimes crap builds up and can form an obstruction. blasting it out with pressurized water can fix it if thats the case
__________________________________________________
|
|
March 29th, 2015, 04:51 AM | #37 |
Rev Limiter
Name: Jay
Location: WI
Join Date: Jul 2013 Motorcycle(s): '06 SV650n, '00 Derbi GPR, '64 CA77 Dream 305, '70 CL450 Scrambler, numerous dirt bikes Posts: A lot.
MOTM - Jun '18, Oct '16
|
Does it have a working radiator fan? If it's that hot, the fan should be running.
Does it have a temp gauge? If so, is it reading in the red when this happens? |
|
March 29th, 2015, 06:25 AM | #38 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
|
Temp gauge and radiator fan are fine. But the coolant is boiling out the overflow bottle, eventually the level drops enough for the bike to get rather hot (not into red zone on temp gauge but very close)
I think it is a minor head gasket failure, letting compression gases from cylinder into the cooling system |
|
March 29th, 2015, 07:05 AM | #39 |
ninjette.org certified postwhore
Name: S
Location: CA/MA, usually
Join Date: Nov 2012 Motorcycle(s): 2012 Ninja 250R, 2007 Ninja 650R, 2001 F650 Dakar Posts: A lot.
|
So much drool.....
|
|
March 29th, 2015, 07:09 AM | #40 |
-
Name: -
Location: -
Join Date: May 2009 Motorcycle(s): - Posts: A lot.
|
I think: That the overheating problem is due to lack of coolant circulation. Because it isn't circulating the portion of the coolant in the engine's cylinder head overheats and boils during operation.
(B.T.W. This is probably why the prior owner wired the radiator fan to run constantly. The failure that is causing the lack of coolant circulation might have developed slowly so running the fan constantly might have helped for a while.) Two things could be causing this: 1. failure of the thermostat to open (or failure to open completely). 2. failure of the water pump to circulate a sufficient amount of the coolant. (and, if the water pump is failing it could be at least a partial cause of the "noisy engine" problem you've been troubleshooting) Be careful with this situation, repeated overheating of the cylinder jacket and cylinder head can warp them. After that happens you'll have a hard time rebuilding the engine. |
|
Similar Threads | ||||
Thread | Thread Starter | Forum | Replies | Last Post |
Yamaha FZR250R 3LN3 | Linkin | Videos | 5 | January 23rd, 2015 07:56 PM |
Is this the toughest Kawasaki restoration project? | Ninjinsky | General Motorcycling Discussion | 2 | January 6th, 2015 06:53 PM |
1983 GR650 Restoration - Where to start? | Maielstrom | The Ex-Ninjetters Lair | 4 | September 16th, 2013 08:51 AM |
Ninjette Decal Restoration of Discussion. | Verus Cidere | Forum Information | 134 | October 20th, 2010 10:51 AM |
Tune up / Restoration questions - long post | Tommy | 1986 - 2007 Ninja 250R Tech Talk | 32 | June 26th, 2009 08:57 PM |
|
|