The attempted repair of the $250 ZXR-250

Discussion in 'Kawasaki 250cc In-line 4's' started by biscuit, Mar 23, 2015.

  1. biscuit

    biscuit Member

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    Hi all, came here looking for PDF info on a ZXR my neighbour sold to me for $250.
    Apart from a 40mm hole in the block, some light drop damage and a keyswipe on the tank, it guess you might say it was O.K.

    I believe the cause was a piston shattering from over revving.

    The motor is now out and about to be split open, I plan to travel to Melbourne for 10 days (unemployed) to use a (dads) lathe and mill to machine up patch plates for the block and send it off for tig welding.

    I only have low res nokia photos for now, when I get my Canon Ixus back I'll take some carnage and resurrection photos.

    It'll be a street fighter with pro taper bars and a milk crate on the back.
     
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  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  3. biscuit

    biscuit Member

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    Thanks Grey!
     
  4. Moo

    Moo Plodge Racing!!!

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    welcome along and happy posting......im curious.....why a milk crate??
     
  5. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    For carrying copious amounts of beer, of course!
     
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  6. Moo

    Moo Plodge Racing!!!

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    ahhhhhhhh now i get it, how could i be so silly :p
     
  7. risky

    risky risky

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    look around and buy another motor.
     
  8. kiffsta

    kiffsta Senior Member

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    is it an A or C model, I have an A model engine in Brisbane

    Chris
     
  9. biscuit

    biscuit Member

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    The milk crate is for biscuits to go in, I was looking at a scooter prior.
    I felt that 6 monthly 2 stroke rebuilds and tailgating, red eyed, gesticulating 4 wheeled motorists was not the way to go.

    At least on a baby 4 cylinder you get 40,000k free and clear if the redline is avoided and good clean fuel going into it.
    And as for those tailgaters, drop it 2 gears and watch em vanish in the mirror.
     
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  10. TechHeadFred

    TechHeadFred Well-Known Member

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    Have a belated :welcome:

    I've been lurking for a while and poked my head out again only recently...
     
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  11. biscuit

    biscuit Member

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    Well it took a whole day to make the girdles that'll help keep the block straight, another day to mill a 'tombstone' block to mount the case on the mill.
    I only pocketed out the upper case this afternoon, luckily the cracks don't appear to run deep.
    I got an ac/dc tig, but not enough experience for dirty alloy welding, anybody know a good tig welder with a cheap hourly rate?
    Has anybody tried the ebay chinese main and bigend bearings?
    They seem a hell of alot cheaper than factory.

    ninja250.jpg
     
  12. biscuit

    biscuit Member

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    Here's closure for you guys, twisted sister good for a door stop..

    Unless your name is surname Millyard, chances are you'll experience the twists.

    twist.jpg
     
  13. Moo

    Moo Plodge Racing!!!

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    sooooo new casings needed??

    great attempt in fixing, that repair job looks neat as!!
     

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