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Project Linkin's FZX250 Zeal

Discussion in 'Your 250cc Projects' started by Linkin, Jun 13, 2016.

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  1. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Doesn't feel like it according to the butt dyno
     
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    Linkin, Sep 8, 2016
    #121
  2. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Got the timing chain and valve clearances done today. Learned a few things... zeals do not have the guide with plastic backing between the intake and exhaust cams as the FZR does.

    [​IMG]

    Did the usual with the chain, except used a small ziptie to hold the chains together this time. Wound engine backwards (not dangerous as the cams are out and all valves are closed) to feed the new chain in.

    [​IMG]

    [​IMG]

    The new chain was not endless, so it has to be joined. Would need to be done anyway unless you feel like splitting cases. Having the correct tools to do the job makes it less frustrating and easier to do - case in point - EMGO chain breaker and riveting kit. You use the blank anvil and the cap over the correct pin for timing chains (2.2mm I think) and squish the new pin into the cap, so that it doesn't fall out. Genius!

    [​IMG]

    Position normally useless ziptie ends into the timing chain to hold the links together. This helps sooo much, if you've ever done a timing trying to hold the links together by hand, this is a revelation.

    [​IMG]

    Change the anvil on the riveting tool for the hollow one and you can begin to send the pin home.

    [​IMG]

    [​IMG]

    Then the pin has to be peened like the rest of the chain. Use the blank anvil and squish the pin on both sides, check that the link moves freely. Job done. Begin putting everything back together.

    [​IMG]
     
    • Like Like x 5
    Linkin, Sep 19, 2016
    #122
  3. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    very nicely done
     
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    ruckusman, Sep 19, 2016
    #123
  4. Phil

    Phil Senior Member Contributing Member

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    Great job @Linkin, the emgo tool seems to work a treat. Last time I did a cam chain found that 2 hands were simply not enough to complete the task, very impressed and well done mate :thumb_ups:
     
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    Phil, Sep 20, 2016
    #124
  5. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    the cable tie keeping the links together is a clever touch, I've used drill bits of the appropriate diameter on drive chains.

    What's the time to change the chain approximately? now that you've done it, quicker the second time?
     
    ruckusman, Sep 20, 2016
    #125
  6. Joker

    Joker See "about me" for contact details. Contributing Member

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    Good job. I took a gamble with a cheap chain breaker kit off ebay as I expected to only use it once - although it did the job I'd consider it substandard for regular use. Metal in the kit bent easily, edges where prone to cold working (it flattening out) so I had to grind the tip off to keep using it. Buy a more quality kit if it's a frequent thing for sure.
     
    Joker, Sep 20, 2016
    #126
  7. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Quicker second time yes. You have to drop the radiator out. Tank off to reach the tensioner. But thankfully no fairings to speak of on the zeal and easy access to the cams thanks to the forward incline of the engine, which also helps to stop the chain falling in.

    I started around 4PM and finished about 9:45.
     
    Linkin, Sep 20, 2016
    #127
  8. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Chucked a new radiator cap on as I could hear the old one hissing after turning off the bike... Fancy one with the safety lever.

    [​IMG]

    Been doing some preliminary tuning of the pilot fuel screws, but it's hard to get a good temperature reading on the headers through all the rust. Booked in for a dyno run on monday.
     
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    Linkin, Sep 22, 2016
    #128
  9. kiffsta

    kiffsta Senior Member

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    You have a bike dyno in Tamworth ?
     
    kiffsta, Sep 22, 2016
    #129
  10. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Yeah there are 2 that I know of... The harley place (Western Ranges) and a smaller guy who runs his own shop... 100 bucks for 3 runs
     
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    Linkin, Sep 22, 2016
    #130
  11. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    We are a progressive town in some ways. :D
     
    Murdo, Sep 22, 2016
    #131
  12. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    I'd love to see you roll into the harley place and request a dyno run, I imagine sneers and sideways glances to which you could counter, well at least mine goes around corners :D

    I am of course just being cheeky
     
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    ruckusman, Sep 22, 2016
    #132
  13. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    They are also a honda and susuki dealer so they appreciate sports bikes too :thumb_ups:
     
    Linkin, Sep 22, 2016
    #133
  14. kiffsta

    kiffsta Senior Member

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    Just put Some saddlebags on it
     
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    kiffsta, Sep 22, 2016
    #134
  15. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    and training wheels so you can't go around corners quickly :D:p
     
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    ruckusman, Sep 22, 2016
    #135
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