March 29th, 2015, 01:58 PM | #41 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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The radiator fan is not running all the time, it comes on and off on its own.
I checked the waterpump / impeller, it's not broken. https://www.youtube.com/watch?v=lxgm0ZytOxY |
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March 29th, 2015, 04:55 PM | #42 |
-
Name: -
Location: -
Join Date: May 2009 Motorcycle(s): - Posts: A lot.
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okay, I was wrong... next contestant.
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April 8th, 2015, 05:50 PM | #43 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Head gasket aside for now, I'd been eyeing up a new exhaust for a while... and it arrived today
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May 6th, 2015, 03:26 AM | #44 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Head Gasket change prep. Engine block comes off the bottom end and has its own steel gasket on these bikes. Have a spare in case the bores are cracked or something
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May 7th, 2015, 01:05 AM | #45 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Multiple issues here. One nut was finger tight, so that doesn't help at all. Smelled horrid. Oil was very burnt and black. You can see that one of the long bolts came out with the head. I'll get to that in a bit.
The head gasket was not blown, but still a bit gross So, the bolt that came out with the head. It was in the wrong way!!! The long thread goes into the block/bottom end and the short thread is for the nut on top. The nut seized on the long thread, I had to clamp the bolt in a vice grip and use a breaker bar to get it off. Now, the threads on either end... |
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May 10th, 2015, 01:23 AM | #46 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Taking all the valve buckets and shims out. All of them except a few were ~0.65in, the rest ~0.6in
Yucky exhaust valves Poured petrol into the valves to check for leakage... I will let the pictures speak for themselves. |
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May 10th, 2015, 01:05 PM | #47 |
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.
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your bike > our bikes ...... lol
__________________________________________________
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 |
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May 10th, 2015, 06:18 PM | #48 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Took the head over to a friend's place who kindly showed us what is what when it comes to valves etc, lent me the tools to get all the valves out & gave good instructions for cleaning and lapping of the valve seat surfaces.
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May 12th, 2015, 01:46 AM | #49 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Today I got all the valves out. All of the valve stem seals were hard as rocks when I pulled them out. I think I got 1 or 2 out in one piece, the rest were destroyed.
I got the block out. Itty bitty wittle pistons! Very dirty at that... Thread in the bottom end does appear to be stuffed, but I haven't forced it in the right way as I did with the spark plug threads (which are usable but not perfect) Wonder if the thread can be re-cut with a thread chaser, or if it needs a helicoil This is the cylinder base gasket. God only knows how it broke there... unless I did it when pulling it off, but I don't think so as I was careful. Luckily, the spare block I bought comes with the same gasket, and a set of pistons. I'm wondering if it would be worth using the spare block & pistons I bought (after having the measured of course) as it saves a lot of cleaning! Also unsure if this is gasket material or oil sludge... the spare gasket is just steel... |
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May 14th, 2015, 06:42 PM | #50 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Making the head and bores flat...
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1 out of 1 members found this post helpful. |
May 15th, 2015, 01:59 AM | #51 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Got the headlight etc out of the way, bracket need to be welded. Mirror mount broke off.
Got one of bolts out of the spare engine, it fits straight, but won't go in very far by hand Got the degreaser out and cleaned the swingarm, rear wheel and other bits. Also greased the chain. Waiting game begins... Need the stem seals, helicoil for that bolt, weld up the front bracket. |
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May 23rd, 2015, 01:30 AM | #52 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Yay chinese parts!
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May 30th, 2015, 02:21 AM | #53 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Still waiting for farkin valve stem seals, so fixing up various bodge jobs from previous owners and/or mechanics... Bike was missing a fuel pump, put in the one from my spare bike, and fixed up the fuel tap on my old mans' bike.
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1 out of 1 members found this post helpful. |
June 3rd, 2015, 02:44 AM | #54 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Old man's FZR250 stopped running and won't start. Checked the valve clearances and it's not pretty. Almost all valves are borderline out of spec and some are way out of spec... See cyl #3 intake valves.
Couple of shims have the numbers worn off or have been ground down... Time to order a shim kit. This is what the shed and concrete slab looks like at the moment... full of fizzers and fizzer parts. Only the yellow one still runs without issues! Also pictured: Vintage Triumph Bonneville, spare FZR250 engine, and various ZXR250/GSX250 parts. |
1 out of 1 members found this post helpful. |
June 7th, 2015, 07:35 PM | #55 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Picked up some stuff
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June 8th, 2015, 03:15 AM | #56 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Washing the head and cylinders in CT18 and hot water... roughly 50/50 mix. A lot of crap came off.
Shiny & Clean New valve stem seals going on. Very easy to get on. Getting the old ones out not so much. Valve lapping. Used the fine paste. Spent the rest of evening hours getting all but one of the valves back in... dropped one of the little tapered bearings or whatever they are. Saw it hit the ground but couldn't find it, getting dark... Finding it will be tomorrow's task. |
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June 8th, 2015, 06:54 AM | #57 |
not an actual panda
Name: dan
Location: philadelphia
Join Date: Aug 2012 Motorcycle(s): 2008 Ninja 250, 2009 CBR600RR (Sold) Posts: A lot.
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June 18th, 2015, 10:42 PM | #58 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Ended up needing 2 helicoils for the long thread. Friend is going to experiment with machining the old pistons to see if it can be done without breaking them. Old oil rings are either out of spec or very close to it.
Old thread Job done |
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June 19th, 2015, 11:14 PM | #59 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Checked the valve clearances with the head off by using the cam caps. Easy to do with the head off, as you don't need to worry about the timing of the crank. As usual, all but one of the valves were out of spec.
On another note, valve shims were posted on the 4th from the USA. Then went to Dubai and left there on the 11th. Landed in Australia and departed Sydney airport on the 12th... and then took a week to be processed by AusPost and scanned into the Granville sorting facility (which happened last night, after I rang AusPost). USPS tracking has been useful. The AusPost tracking says stuff that doesn't even match up with USPS! |
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June 22nd, 2015, 01:36 AM | #60 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Got the shim kit, tomorrow I'll change them on my bike and on my dad's bike.
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June 22nd, 2015, 11:58 PM | #61 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Valve shims changed out. Piece of cake with the head off.
Rearranging shims where possible to avoid using up the shim kit. We added the shims from the spare engine into the kit as well. |
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June 28th, 2015, 06:02 PM | #62 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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New decal kit arrived
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June 29th, 2015, 12:56 AM | #63 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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So the issue with gaps between the head and the bores has been solved. The EvilBay bores are the cause. The original bores fit fine with no gaps.
2nd attempt at re-assembly halted though, due to one of the helicoils failing... caused by a little bit too much torque, due to an oopsy with the torque wrench. Completely my fault. 3rd attempt (and hopefully final assembly) begins tomorrow So close!!! |
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June 29th, 2015, 05:45 AM | #64 |
dirty boy
Name: Joe
Location: Johnstown, PA
Join Date: Sep 2012 Motorcycle(s): I don't even know anymore?? Posts: A lot.
MOTM - Apr '14
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looks good. Will be worth it when it is all said and done
__________________________________________________
I love the smell of burning pre-mix in the morning I don't think I'm a lot dumber than you thought that I think that I thought I was once. |
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June 30th, 2015, 01:47 AM | #65 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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June 30th, 2015, 07:25 PM | #66 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Postman dropped by and had some goodies for me
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July 2nd, 2015, 03:18 AM | #67 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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July 2nd, 2015, 05:43 AM | #68 |
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.
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Sweet!!!!
__________________________________________________
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 |
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July 4th, 2015, 12:20 AM | #69 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Put the rest of the plastic pieces on today. Fuel tap is leaking a lot less with better screws. Still have a little coolant leak out of the one the hoses to sort out, but running great. Have also finished tuning the idle circuit on the carbs, uploading that video soon.
The Yellow Peril is looking a bit sad at the moment. Little bit of Inox on the switch blocks & dash does wonders |
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July 4th, 2015, 12:37 AM | #70 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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July 6th, 2015, 09:36 PM | #71 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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July 13th, 2015, 05:27 AM | #72 |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Carb problem has been fixed... 2 bolts and a spring to keep track off and the 2 banks of carbs split apart. No messing with sync or balance at all!
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1 out of 1 members found this post helpful. |
July 16th, 2015, 07:26 AM | #73 |
Inline 4!!!
Name: Danny
Location: MA
Join Date: May 2014 Motorcycle(s): 2008 CBR600rr, 1987 KLR 250 Posts: A lot.
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Finally a build/restoration thread that appears to be seeing an end in sight! You've done a lot to that bike, this thread has been very entertaining to read through.
-I don't mean to be "that guy", but please wear a helmet though when riding. Even if it is just down the street.
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Be careful. Remember you are invisible |
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July 17th, 2015, 02:54 AM | #74 | |
Down Under
Name: Linkin
Location: Sydney, Australia
Join Date: Jun 2014 Motorcycle(s): Kawasaki ZXR250C Ninja Posts: 296
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Quote:
The blue whore virgin is basically done. The last things to do are to replace the tyres (or wear out the existing ones), replace the fuel tap seals and change 1 coolant hose. I will be getting my tax refund on Monday which gives me a few grand to play with for the other bike, I'll be making a separate thread for that. |
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July 17th, 2015, 03:43 AM | #75 |
Freedom for Germany
Location: This World
Join Date: May 2011 Motorcycle(s): Ninja 250R-FI Posts: A lot.
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