My ZZR 250 Rebuild (image heavy)

zzrguy · January 31st, 2012, 02:58 PM

My rebuild story

Was riding my bike one day and my engine stopped working and i heard a chain slapping around... it was my cam chain and the tensioner broke causing it to not work. i took the whole engine apart and rebuilt it from bottom up just thought id share my pictures from the rebuild

if anyone ever has a 250 engine question just ask :P I have a good understanding of it not to mention I'm almost done school for motorcycle tech

If you have questions feel free to ask

Pistons

Before

After

Honed out the cylinders

Took everything out and cleaned her up

Valves before cleaning

Valves after cleaning

if your wondering why my surface looks bad its because i had a gouge in it and i had it removed... yay for higher compression ratio lol hope the engine lasts long ill tell you guys how it goes when i fire it up next week.

clutch about to come off make sure when you put your clutch back on you align the two dots there is one on the top and one on the bottom but its hard to see the bottom as its blurry.

You can see the clutch off as well as my epic engine stand that I threw together in a few hours

Split the cases

make sure when you take out the crankshaft and the counterbalance to re-align them, you can see i put a red line across the two of them, there is two dots but the line helps ya remember.

Cases emptied out and cleaned up

make sure to organize your parts, makes a hell lot easier to put it back together..

had a ton of fun other than waiting 10 years for parts! but good thing winters over now that its done.

nickjpass · January 31st, 2012, 03:02 PM

Ten years!?!?

zzrguy · January 31st, 2012, 03:03 PM

Quote:

Originally Posted by nickjpass

Ten years!?!?

lol okay 4 weeks but it felt like 10 years :P stupid back ordered parts

choneofakind · January 31st, 2012, 03:26 PM

wow this looks really good man.

Now follow the moto-man method of break-in, and you'll have more hp, on top of that little extra from slightly higher compression

Should have done some porting while you were in there

zzrguy · January 31st, 2012, 03:39 PM

Quote:

Originally Posted by choneofakind

wow this looks really good man.

Now follow the moto-man method of break-in, and you'll have more hp, on top of that little extra from slightly higher compression

Should have done some porting while you were in there

Thanks man and moto man method?
I did lap the valves and seats :P

choneofakind · January 31st, 2012, 04:28 PM

the moto-man method is basically run it hard in a controlled manner so that it breaks in the parts that need broken in asap, and do oil changes early to get rid of the metal shavings. Makes sense to me.

check out this thread

nickjpass · January 31st, 2012, 09:59 PM

Quote:

Originally Posted by zzrguy

lol okay 4 weeks but it felt like 10 years :P stupid back ordered parts

You made me think it was impossible to get those parts

NDspd · February 1st, 2012, 08:40 AM

Dude that's freaking awesome to see what makes our bike tick...thanks for the explanation and the pics!!!

gilmorec61 · February 1st, 2012, 08:47 AM

Wow man, that looks pretty sweet! Also extremly confusing, but i hope that one day i will learn how to do something like that and NOT mess up.

But cool to see what the engine looks like on the inside! Gotta let us know how she ticks after the rebuild!

SlowBoyRacing · February 1st, 2012, 02:03 PM

Quote:

Originally Posted by gilmorec61

Wow man, that looks pretty sweet! Also extremly confusing, but i hope that one day i will learn how to do something like that and NOT mess up.

But cool to see what the engine looks like on the inside! Gotta let us know how she ticks after the rebuild!

Not confusing at all once you have it all in front of you. If you have a factory service manual helps things a lot. Just make sure to follow the torque specs and (if any) tightening sequences, the rest all comes with practice and experience.

January 31st, 2012, 02:58 PM	#1
zzrguy ninjette.org member Name: Lostboy Location: Guelph Join Date: May 2011 Motorcycle(s): 2002 ZZR 250 Posts: 127	My ZZR 250 Rebuild (image heavy) My rebuild story Was riding my bike one day and my engine stopped working and i heard a chain slapping around... it was my cam chain and the tensioner broke causing it to not work. i took the whole engine apart and rebuilt it from bottom up just thought id share my pictures from the rebuild if anyone ever has a 250 engine question just ask :P I have a good understanding of it not to mention I'm almost done school for motorcycle tech If you have questions feel free to ask Pistons Before After Honed out the cylinders Took everything out and cleaned her up Valves before cleaning Valves after cleaning if your wondering why my surface looks bad its because i had a gouge in it and i had it removed... yay for higher compression ratio lol hope the engine lasts long ill tell you guys how it goes when i fire it up next week. clutch about to come off make sure when you put your clutch back on you align the two dots there is one on the top and one on the bottom but its hard to see the bottom as its blurry. You can see the clutch off as well as my epic engine stand that I threw together in a few hours Split the cases make sure when you take out the crankshaft and the counterbalance to re-align them, you can see i put a red line across the two of them, there is two dots but the line helps ya remember. Cases emptied out and cleaned up make sure to organize your parts, makes a hell lot easier to put it back together.. had a ton of fun other than waiting 10 years for parts! but good thing winters over now that its done.

January 31st, 2012, 03:02 PM	#2
nickjpass #squid Name: nickypoo Location: Five Guys Join Date: Jul 2011 Motorcycle(s): Track dedicated 2008 ZX6R Posts: A lot. MOTM - Jul '16	Ten years!?!? __________________________________________________

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January 31st, 2012, 03:26 PM	#4
choneofakind ninjette.org certified postwhore Name: . Location: . Join Date: Feb 2011 Motorcycle(s): . Posts: Too much. MOTM - Feb '13, Feb '14	wow this looks really good man. Now follow the moto-man method of break-in, and you'll have more hp, on top of that little extra from slightly higher compression Should have done some porting while you were in there

January 31st, 2012, 04:28 PM	#6
choneofakind ninjette.org certified postwhore Name: . Location: . Join Date: Feb 2011 Motorcycle(s): . Posts: Too much. MOTM - Feb '13, Feb '14	the moto-man method is basically run it hard in a controlled manner so that it breaks in the parts that need broken in asap, and do oil changes early to get rid of the metal shavings. Makes sense to me. check out this thread

February 1st, 2012, 08:40 AM	#8
NDspd 1/4 English, 3/4 Kick Ass Name: Jeremy Location: Dayton, OH Join Date: Sep 2011 Motorcycle(s): 2002 Triumph Speed Triple 955i, '05 Suzuki SV650S(retired), '11 Ninja 250R(sold) Posts: A lot.	Dude that's freaking awesome to see what makes our bike tick...thanks for the explanation and the pics!!!

February 1st, 2012, 08:47 AM	#9
gilmorec61 ninjette.org guru Name: Chris Location: Newnan, G.A. Join Date: Jan 2012 Motorcycle(s): 2008 Kawasaki Ninja 250R Posts: 347	Wow man, that looks pretty sweet! Also extremly confusing, but i hope that one day i will learn how to do something like that and NOT mess up. But cool to see what the engine looks like on the inside! Gotta let us know how she ticks after the rebuild!