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Shaun's ZXR250 A model Build Thread

Discussion in 'Kawasaki 250cc In-line 4's' started by zxaar, Jul 2, 2013.

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  1. risky

    risky risky

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    i dunno what a new gas analiser costs but the one where the honda dealer at ferntree gully went under sold at auction for over 2 grand.
     
    risky, Jul 5, 2013
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  2. zxaar

    zxaar Member

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    Made a bit of progress today. I degreased the motor and the frame. The motor is now partially installed but I've only put the lower engine mount in so it sits lower making it easier to install the electrics, hoses,ect. The carbs are in too now so I'm getting there slowly now but damn it was hard to install that lower engine mount:headbang: If only I had 3 arms lol. Just had a short lunch break and now it's time to get back into it :)
     

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    zxaar, Jul 5, 2013
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  3. zxaar

    zxaar Member

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    I'm having a bit of drama trying to figure out where two hoses go. One goes into the carbs at the front where the diaphram is which is a single hose that connects to a T piece and the other hose also connects to a T peice but it comes from the float side. The manual doesn't help...
     
    zxaar, Jul 5, 2013
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  4. zxaar

    zxaar Member

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    Both of these hoses come from the carbs. One is on the front and one is on the back
     
    zxaar, Jul 5, 2013
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  5. kiffsta

    kiffsta Senior Member

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    On the top of the carbs are 2 hose outlets, they go to a t piece and long hose that connects to the top of the air box, underneath the carbies on the intake manifolds are 4 smaller diameter hoses, 2 join to each other and the other 2 join to a t piece that is the return line to the tank.. does that help ?
     
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    kiffsta, Jul 5, 2013
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  6. zxaar

    zxaar Member

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    That was exactly what I needed to know. Thanks mate :) I had a feeling that's where they went to but wasn't 100% I will be labelling everything from now on just to be sure.
     
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    zxaar, Jul 5, 2013
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  7. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    I found taking before photos , labeling things like hoses and wiring when unplugged and bagging things that came off for more than 2 seconds was the best way to keep track of whats doing ...and so much easier at reassembly..... I had a few nuts, bolts ,screws and bits left that were a mystery but having boxes full of spares and a spares bike accounted for that .... thats my reasoning anyway :D
     
    GreyImport, Jul 5, 2013
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  8. zxaar

    zxaar Member

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    I agree, Unless you have disassembled your bike more than a few times and know it back to front then photos and labelling is a fool proof way of getting it all back together correctly.
    I think we have all been down the road of forgetting where things go or having a container full of "left over" nuts and bolts but I must be doing something right as there is not one left over. I do need to learn to remember what goes where though...
    It's always easier to pull something to bits but the real test is in the reassembly. I plan on keeping my ZXR long term so I can only become more familiar with her as time progresses.
     
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    zxaar, Jul 5, 2013
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  9. zxaar

    zxaar Member

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    I got the bike back together this morning and fired her up. Besides the fan not coming on whatsoever the motor is idling perfectly at 1500rpm and revs nicely. Now to wire the fan to the ignition and a few other bits and pieces like the fairings,ect. Very happy with it now :)
     
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    zxaar, Jul 6, 2013
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  10. zxaar

    zxaar Member

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    Also I forgot to mention that before I started it I turned the motor over for around 10 seconds(2X 5seconds) to build up oil pressure then primed the carbs for around 15 seconds.
     
    zxaar, Jul 6, 2013
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  11. risky

    risky risky

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    WELL DONE.
     
    risky, Jul 6, 2013
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  12. zxaar

    zxaar Member

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    Just put the chain on and a few other bits and pieces. Took her for a quick spin and yeah, it's definitely got full compression. Goes VERY well, I'm really happy with it. The temp doesn't go above that bottom line now that the fan is wired to run when the ignition is switched on so there's no more overheating issues anymore.
     
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    zxaar, Jul 6, 2013
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  13. risky

    risky risky

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    buy a temp switch on ebay[chinese?]and in the long run you will be happier.
     
    risky, Jul 6, 2013
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  14. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Excellent stuff Shaun ..... :thumb_ups:
     
    GreyImport, Jul 6, 2013
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  15. Phil

    Phil Senior Member Contributing Member

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    Well done Shaun, you the man. Seems like only yesterday that we were loading her on the trailer, the dust has hardly settled and you are mobile, Bravo mate :thumb_ups:
    I agree with risky, grab a cheap temp switch on ebay, the fan on constantly will drive you nuts. Again, well done :)
     
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    Phil, Jul 6, 2013
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  16. zxaar

    zxaar Member

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    Thanks guys. I'll have a look on Ebay and see what temp switches they have.
     
    zxaar, Jul 6, 2013
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  17. zxaar

    zxaar Member

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    It's starting to come together nicely now. On the to-do list now is repair the fairing where the right indicator goes, fit the right indicator, fit the front brakes, new chain, temp switch, full service and then the roadworthy cert.
     

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    zxaar, Jul 6, 2013
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  18. risky

    risky risky

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    if you cannot find on aus ebay look at usa ebay as the range is greater there.
     
    risky, Jul 7, 2013
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  19. zxaar

    zxaar Member

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    Hey guys, looking for a new chain at the moment and was wondering if this 120 link chain is the right one.

    http://www.gearfactor.com.au/catalog/item/7626966/8078212.htm

    Also I noticed that my bike has a 13 tooth front sprocket(14T standard) and wanted to know if I would also need to purchase a chain breaker for the chain to be the right length.
     
    zxaar, Jul 11, 2013
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  20. kiffsta

    kiffsta Senior Member

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    kiffsta, Jul 11, 2013
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