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Project Risky's FZR250 2KR

Discussion in 'Your 250cc Projects' started by Linkin, Feb 19, 2016.

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  1. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    My Bike:
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    When Risky came up to to Tamworth with @Grasshopper 's FJR1300AE on the trailer, it was accompanied by another bike.

    Right now this 2KR is not running, due to a wiring issue I think, you press the starter and the oil light comes on.

    Other than that it is a bit rusty, so it will be torn down to have the frame and swingarm refurbished. It is also home to many arachnids, living and dead, who will have to be evicted before I pull it apart!

    [​IMG]

    [​IMG]

    I have a shopping list of supplies, which mostly involves labelling and storage of parts as not to get them mixed up (ther are a LOT of bike parts in the workshop at the moment)

    Expect more pictures this weekend :D
     
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    Linkin, Feb 19, 2016
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  2. risky

    risky risky

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    was running but has been sitting. suspect corossion somewhere.
     
    risky, Feb 19, 2016
    #2
  3. Murdo

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

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    Doesn't look too bad.
     
    Murdo, Feb 20, 2016
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  4. kiffsta

    kiffsta Senior Member

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    Cant wait to see how this one goes, we dont get too many 2kr builds here
     
    • Like Like x 1
    kiffsta, Feb 20, 2016
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  5. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    My Bike:
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    It isn't horrible, but things are a bit rusty, the frame and forks especially.

    I'm liking it already, certain items are laid out/positioned better than the 3LN's, such as the radiar cap and overflow bottle cap. Not as many bits holding the fairings on. It's quite easy to work on.

    [​IMG]

    [​IMG]

    Speaking of fairings, they are off...

    [​IMG]

    This bike has an EXUP servo motor and valve on the exhaust, says EXUP on the exhaust, so safe to say that this bike is a 3HX, but I haven't looked at the frame/engine numbers yet.

    [​IMG]

    Starting to look familiar.

    [​IMG]

    [​IMG]

    [​IMG]

    Have to see if new intake boots can be sourced.

    Bonus pics - Home for Ageing Arachnids

    [​IMG]

    [​IMG]

    [​IMG]
     
    • Like Like x 2
    Linkin, Feb 20, 2016
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  6. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    All the grey bikes were just thrown into shipping crates and sent out onto the high seas. That's why they all have rust issues. Best to pull apart, paint & plate. Now is this number 4 Fizzer or number 5?
     
    maelstrom, Feb 20, 2016
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  7. risky

    risky risky

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    have put in buying request on alibaba.com. will check shed in morning.
     
    risky, Feb 21, 2016
    #7
  8. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Well the boots look OK on the inside couldn't see any holes but doesn't mean they aren't leaking.

    Engine number, matches the frame. Makes it a 3HX1.

    [​IMG]

    Carbies out. Something funky going on with #4, the throttle body is jammed.

    [​IMG]

    Someone has been living in #1 intake... this airbox boot had popped out of the airbox (which was held down via zipties)

    [​IMG]

    Carbs look fairly clean but they are probably not all that clean in the jets. No funky green stuff like my 3LN6 carbs though.

    [​IMG]

    Someone had already made swiss cheese of a few JIS screws which will need to be drilled out before any further work on the carbs.
     
    Linkin, Feb 21, 2016
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  9. risky

    risky risky

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    i have several sets of 2nd hand boots and carbies. let me know what is required. do not have a new cam chain though.
     
    risky, Feb 21, 2016
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  10. steve1467

    steve1467 Active Member

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    I'm working on rebuilding a FZR250 2kr model for my wife. I've hit a wall for carb parts. I can find seals etc but I need jets and needles. Does anyone have these parts or can suggest where I may find these parts. Cheers
     
    steve1467, Feb 22, 2016
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  11. risky

    risky risky

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    no idea personally.
     
    risky, Feb 22, 2016
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  12. kiffsta

    kiffsta Senior Member

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    Last edited: Feb 22, 2016
    kiffsta, Feb 22, 2016
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  13. steve1467

    steve1467 Active Member

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    Thanks kiffsta this kit is exactly what I'm after. Hopefully have the good lady on the road soon.
    Next project is the FZR1000 rebuild for me so this website is going to be very handy.
    Cheers mate
     
    steve1467, Feb 22, 2016
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  14. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Those are the Keyster tuning kits. They give you the jets and needles either side of standard so you can mess about. A lot of those parts are not available for the OEM carbs.
     
    maelstrom, Feb 22, 2016
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  15. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    More work today. I was out and about getting supplies like o-rings, screws, and something to seal the crankcase halves when I put them back together. Threebond 1215 is what I got, but it only came in 250 grams, nothing smaller... so I will get plenty of uses out of it.

    I've dismantled the rest of the cooling system and put it in a container, and got the engine out. It was a lot easier to do myself compared to a 3LN, which is a 2 man job. I should be able to get the engine back in myself when the time comes.

    [​IMG]

    [​IMG]
     
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    Linkin, Mar 7, 2016
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  16. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Started taking the engine apart today and trying to remove stuck gaskets without breaking them... Not much luck, and there's a set of new ones there anyway, so I focused on cleaning up the gasket surfaces.

    There are also these numbers stamped onto the crankcase. I wonder if they are the bearing codes/sizes for the big ends and mains?

    [​IMG]

    Off with it's head...

    [​IMG]

    Gasket OK.

    [​IMG]

    Barrels looking good

    [​IMG]
     
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    Linkin, Mar 9, 2016
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  17. risky

    risky risky

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    any marks in the bores?how did the rings look? still have tension?valve appearance and seat shape?
     
    risky, Mar 9, 2016
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  18. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Bores look OK, a bit of carbon on the lip but nothing that won't clean out.

    All valves look OK on brief visual inspection but have not started taking them out yet.

    Rings, haven't checked yet.
     
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    Linkin, Mar 9, 2016
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  19. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    My Bike:
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    GreyImport, Mar 9, 2016
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  20. kiffsta

    kiffsta Senior Member

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    checked the seat, should be okay for a few more kms

    [​IMG]
     
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    kiffsta, Mar 9, 2016
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