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Huntsman's Kawasaki ZXR250A

Discussion in 'Kawasaki 250cc In-line 4's' started by Th3_Huntsman, Jul 15, 2013.

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  1. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    Had a win today, I got the intank filter out! So the tank Is having an overnight soak in vinegar and bi-carb soda. Hoping for good weather tomorrow!

    image.jpg image.jpg
    Why did it take me so long to buy one of these! Cheers for the tips boys!!
     
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    Last edited: May 16, 2014
    Th3_Huntsman, May 16, 2014
    #181
  2. TechHeadFred

    TechHeadFred Well-Known Member

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    Just read through the whole thread. The difference in sound is really noticeable in the the three videos!
    Great work Hunstman!

    Those claw things are awesome - I had a little one in a PC toolkit a while ago.

    I've found the telescopic magnet that came with my "go-to" bike toolkit for smaller jobs (a $25 Supercheap one I think) has come in handy for screws dropped in the lawn at least a couple of times lately!
     
    TechHeadFred, May 16, 2014
    #182
  3. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    Thank you Fred! I Appreciate it:drinks: You are right about the difference, as it's currently getting me to and from work everyday :dance2: next on the list is a brake rebuild and then to tidy the fairings and paint up. And once I've learnt how to do fork seals on my other zxr it's time for a fork oil change.
     
    Th3_Huntsman, May 16, 2014
    #183
  4. zixxer

    zixxer Well-Known Member

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    cleaned mine up and replaced a couple seals, there was sludge stuck on the bottom of the pistons, seals from a store are 12 bucks new from kawasaki so go on ebay and get the seal rebuild kit, works perfect.

    also got my ebc brakes gonna put them on and go for a spin tommorow, will see if they are better than the standard pyramid parts.
     
    zixxer, May 17, 2014
    #184
  5. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    FYI vinegar and bicarb just neutralises and bubbles off CO2 - unless you meant vinegar prior to a flush and then bicarb to neutralise any remaining acid.

    Electrolysis give great results

    http://2fiftycc.com/index.php?threads/rusty-fuel-tank-electrolysis.1809/

    peace out
     
    ruckusman, May 17, 2014
    #185
  6. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    That's what I meant ruckus, cheers, I have a kbs kit I'm putting in it as it keeps springing pin holes anyhow so the kit is comin up gangbusters so far :)
     
    Th3_Huntsman, May 17, 2014
    #186
  7. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    The tank kit step by step photos
    All previous patch work...
    patches.jpg dent.jpg patch job.jpg
    after soaking in vinegar. the corners deep in the tank are still dreadful
    after degrease.jpg step one is a degrease so easy enough, here is a pic mid step 2 rustblast.
    some rustblast.jpg
    After the rustblast lookin good
    after rustblast.jpg
    Sealant in the tank halfway through the first curing stage
    sealer kit done.jpg
    looks like I have a couple of puddles and now I have to wait and see that it takes I hope so!
     

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    Th3_Huntsman, May 18, 2014
    #187
  8. Phil

    Phil Senior Member Contributing Member

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    The tank on the Bandit looked pretty tidy prior to paint, therefore did not deem it necessary to coat it at the time.
    Several months later leaks appeared so a sealant was applied, and problem solved but alas returned a third time.
    Used an external sealer and haven't had any further problems. Devcon saved the day.:thumb_ups:
     
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    Phil, May 18, 2014
    #188
  9. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    So my day started out well, I had to patch my seal kit as it split on one spot for some reason so yesterday I patched it with cold weld as it is fuel resistant. And left that over night. Well it took so I went about putting the bike back together. All good

    Gave the bike a wash and went to go for a blast up mt tamborine to celebrate having a yellow bike again! Then things went pear shaped. Just around the block it just died plain and simple no lights or dash lights. I figured out it was the 30a fuse on the starter solenoid.
    image.jpg
    So I get pushing get to the driveway and try to go up the gutter then I drop the ******* thing :mad: I broke the mirror completely off and hurt the tingate pipe :(. A positive is in my box of spares the mirror I had happened to be a right one. So that's a win.
    image.jpg
    It is now at a state of randomly blowing the new fuse I put in, most of the time it is on the turn of the key and others it will let me start it and run then blow. I have swapped out the starter solenoid. Any ideas? What did I wet with the wash?

    I found a limited edition red sticker chris gave me at the last ride day in my jacket so it has been applied to the $100 wagon to raise the value lol
    image.jpg
     
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    Th3_Huntsman, May 25, 2014
    #189
  10. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    Its all good guys I just wet something I shouldn't have but now I have 5 spare 30a fuses in the bike lol. God I hate pushing my bike:minigun: haha
     
    Th3_Huntsman, May 26, 2014
    #190
  11. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    My bike wouldn't start and flattened the battery on Friday morning so peeved as it made me late for work. So I bought a motobatt for it and a multimeter so I could check the charging system all seems ok my battery must have been weak after being charged a few times.

    So today I set about rebuilding the brakes as my brake pads came in, holy hell what a mission. I managed to get all the pistons out eventually. I actually hooked the caliper back up and re bled the system for the worst caliper as the compressor just wouldn't get them to budge. So I used the hydraulics of the brakes themselves and wished I had done this to begin with as it was much easier. Doh!

    All the brakes are soaking overnight now as there was a lot of gunk built up.
     
    Th3_Huntsman, Jul 12, 2014
    #191
  12. Phil

    Phil Senior Member Contributing Member

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    Isn't life grand, do you ever wonder what you'd be doing if you weren't the proud owner of a motorbike.:lolsign:
    Good to hear you got the pistons out of your callipers, never an easy job. One small piece of advise Tyson,
    get the groove that the seal sits in spotlessly clean, it's a tedious job but essential for the seal to fit in snug.
    After all you want those pistons to move freely so as to get a firm brake, my 2 cents worth mate, good luck:thumb_ups:
     
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    Last edited: Jul 12, 2014
    Phil, Jul 12, 2014
    #192
  13. kiffsta

    kiffsta Senior Member

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    ZXR250 brakes are a PITA, how did you go Tyson ?
     
    kiffsta, Jul 13, 2014
    #193
  14. zixxer

    zixxer Well-Known Member

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    if you have a small screw thin screw driver you can fit it through the hole where the brake line goes in and push the pistons out a little then use some grips to pull it out completely.
     
    zixxer, Jul 13, 2014
    #194
  15. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    I'm attacking them again now. I need the luck lol. Cheers fellas
     
    Th3_Huntsman, Jul 13, 2014
    #195
  16. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    I was scared of damage, I found if you leave it attached to the brake line and leave one pad in you can just pump the lever and get even the most stuck pistons to move.
     
    Th3_Huntsman, Jul 13, 2014
    #196
  17. zixxer

    zixxer Well-Known Member

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    same thing happened to me, i just couldn't be bothered putting brake fluid in them again so just went for it.

    dont bother going to kawasaki for any new seals, they will slug you 12 bucks per seal.
     
    zixxer, Jul 13, 2014
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  18. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    **** that adds up needing 6 seals and then 6 dust seals.

    Which brake do you reckon was grabbing
    image.jpg
    Ready to be put back together
    image.jpg
    image.jpg
     
    Th3_Huntsman, Jul 13, 2014
    #198
  19. zixxer

    zixxer Well-Known Member

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    yeah it will add up quickly, i just re used mine and had to get a rebuild kit for the rear of ebay.
     
    zixxer, Jul 13, 2014
    #199
  20. Phil

    Phil Senior Member Contributing Member

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    Top photo tells it's own story, well at least you know the problem. You won't know yourself with good and reliable working brakes:thumb_ups:.
     
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    Phil, Jul 13, 2014
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