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Old September 25th, 2022, 11:59 AM   #1
Washburn
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Name: C
Location: Toronto
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Motorcycle(s): 01' Ninja 250r

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Smile 01' 250 restoration.

Currently working on the teardown part of my resto project. I've got some pictures but so far I've just taken the engine off the frame, took the carburetor out and started giving it a bit of clean, though I've got to wait on the rebuild kits so in the mean time I'm just cleaning EVERYTHING from the ground up. This was previously someone's project and I genuinely don't know why things were taken apart where they were but I was assured everything is with it. I've got a 2nd bike which is I believe a 1988 Ninja which was either supposed to be the bike to restore or the parts bike, etc... I'll include some pics as I go along but I was mostly taking pics for reference and joined the forum after

One big question I've been trying to figure out is that if/when I split the engine to get to the gear shift and the other internal components of the engine, how do I seal it back? Is there a gasket I have to get or is it like a rubberized sealant you put on it as you reassemble? I'm completely new to this and moto in general but I've caught a bug for this and I am usually up until the hours of the morning figuring things out. I'm really excited and look forward to the journey.

tldr; new to resto, got some pics, how do I seal an engine back up, really excited.
Attached Images
File Type: jpg carb1.jpg (86.9 KB, 5 views)
File Type: jpg carb2.jpg (72.9 KB, 4 views)
File Type: jpg carb3.jpg (78.1 KB, 4 views)
File Type: jpg moto1.jpg (94.8 KB, 7 views)
File Type: jpg moto2.jpg (93.8 KB, 7 views)
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Old September 25th, 2022, 12:53 PM   #2
Washburn
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Here's some more pics of the engine. Just want to get this split open and to clean all the parts. Also, Gasket or seal where the green line is? I just don't know lol.
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File Type: jpg engine.jpg (77.6 KB, 3 views)
File Type: jpg eng2.jpg (78.9 KB, 0 views)
File Type: jpg eng3.jpg (101.9 KB, 2 views)
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Old September 25th, 2022, 02:47 PM   #3
Washburn
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Yummy.
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Old September 25th, 2022, 02:48 PM   #4
Washburn
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Getting organized
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Old September 25th, 2022, 06:53 PM   #5
DannoXYZ
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MOTY - 2018, MOTM - Nov '17
probably don't need to split cases unless you need to replace main or rod-bearings. No gasket, just thin smear of sealant. Yamabond-4, Toyota 103 FIPG, Permatex Ultra Black (not grey).
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Old September 26th, 2022, 12:55 PM   #6
CZroe
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Another legendary ZZR250 (EX250H). We never got that in USA so I’m jealous of you Canadians! Good luck with the project.
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Old September 26th, 2022, 03:09 PM   #7
Washburn
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Thanks a ton man, I've been pretty anxious about splitting this guy up. That being said, I will have to say that I'm piecing together what the previous owner gave up upon; it's very clean and as far as I can tell they just gave up on the basis of it being too difficult. What's the best way to get the inside of it cleaned out then? I planned on going to the very core of the engine and rebuilding ground up to clean every part but if it doesn't require me to split it open I'd like to get it as clean as I can.

Welp... I do have a spare engine available Georgia and when the time comes to pass and I make my way through the states... just a thought

-C
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Old September 26th, 2022, 04:00 PM   #8
DannoXYZ
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Quote:
Originally Posted by Washburn View Post
What's the best way to get the inside of it cleaned out then? I planned on going to the very core of the engine and rebuilding ground up to clean every part but if it doesn't require me to split it open I'd like to get it as clean as I can.
Insides are sealed if engine was in one-piece and not disassembled when you got it. You can drain oil and send in sample to one of those used-oil analysis places. From metal contents, they can tell if there's unusual wear that requires replacing rings or bearings.

Most of time, running through one sacrificial oil-change for 100km should be all that's needed to clean up inside. Then replace with full-synthetic JASO MA oil.

Of course, not knowing exact condition of engine can be unnerving. Did PO ever have bike running and can verify engine engine didn't make any unusual noises? You can run '88 Ninja engine to see how it sounds. If good, you can put it in ZZR while you take your time with ZZR's engine.

Last futzed with by DannoXYZ; September 27th, 2022 at 01:45 PM.
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Old October 1st, 2022, 09:29 AM   #9
SibSerge
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Hi washburn, I might have the tube of Kawasaki sealant I bought from the dealer a couple of years ago to seal the crevices the valve cover and the clutch cover. I will need to check if I still have it - I am out of the country and will be back next week. I recently sold my ninja and do not need it, if I have it you can come and pick it up for free. I am on the west end if gta
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Old October 13th, 2022, 10:40 AM   #10
Washburn
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Been a bit so here's a quick update. Engine looks great, starting to clean the bike up itself and waiting on some stuff to come in the mail. Should have real updates come the end of October
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