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Project A work in progress my FZR 250 2kr

Discussion in 'Your 250cc Projects' started by downunderfzr, Feb 10, 2017.

  1. downunderfzr

    downunderfzr Active Member

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    I thought i better move (Greetings from new FZR250 owner in Australia)/ start a new thread to this section after the discussion about my work in progress to get my FZR 250 2kr working properly.

    So I'm waiting for my compression tester to turn up but have been busy working on the fairings etc.

    My bike has exup & i noticed that there is no cables connected to the valve on the exhaust - is that correct?
     
  2. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    There should be 2x cable's going from the controller module down to the EXUP valve on the exhuast
    Cable part number's - 3LN-1133E-00 and 3LN-1133F-00
    The YZF 1000 uses the same cables
    Venhill make a cable repair kit, but you'd still need some outer's
    http://www.venhill.co.uk/Hoses_&_Ca...1-11-100_UNIVERSAL_EXUP_CABLE_REPAIR_KIT.html

    [​IMG]

    Someone here might have a pair of cable's ?


    Here's a complete used set up for $52.55 inc post, but just confirn the part number will work on your bike
    http://www.ebay.com.au/itm/Yamaha-F...721640?hash=item41ac9b1fe8:g:ywUAAOSwMNxXYPK9
    Another for $65 inc post
    http://www.ebay.com.au/itm/Yamaha-F...141996?hash=item235f16246c:g:28QAAOSwHPlWcoWB
     
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  3. downunderfzr

    downunderfzr Active Member

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    Thankks
    Just had a look the controller / servo is there & does the forward then reverse action when i switch the ignition on - great!

    Just need the cables then set them up - i wonder why in the past they were removed?
     
  4. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Cable's might have been damaged, or someone didn't know how to adjust it properly
    Was the valve on the exhaust wired open ?
     
  5. downunderfzr

    downunderfzr Active Member

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    No wire, it looks like its shut to me

    018 (3) (800x450).jpg
     
  6. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    What's in the U shaped slot at the top ?
    I reckon it's fully open
    The u shaped slot should be lined up at 9 o'clock with the hole if it's closed
    This is how it should line up when the cable's are adjusted correctly

    And watch out your stand bolt doesn't fall out, it's pretty loose, don't want it falling over

    [​IMG]
     
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  7. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  8. downunderfzr

    downunderfzr Active Member

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    Bolt tightened, thanks again for pointing me in the right direction.
     
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  9. downunderfzr

    downunderfzr Active Member

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    I made up 2 cables from an old push bike brakes, there was half a chain link holding the valve open which has been removed.
    Working as it should now.
     

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  10. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    That top cable look's like it's not seated properly, but that was most likely a before adjustment picture ?
     
  11. downunderfzr

    downunderfzr Active Member

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    Yes your on the money my67xr I had mess around to get the right tension on both cables.
    Hopefully the compression tester turns up tomorrow & work out if the rings etc need attention.
     
  12. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    You look like you're tacking the repairs in a good order, bear in mind that valve clearances will have a BIG impact on compression readings.

    You need to lock the throttle open and prop the carburettor slides open to achieve anything like meaningful readings on the compression test
     
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  13. downunderfzr

    downunderfzr Active Member

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    So still waiting to receive the compression tester -aust post is crap 10 days now melb to perth!
    In the meantime I checked the valve clearances, a big thanks to ruckusman for the great how to.
    Here's a pic of the results, I'm going to do the compression before checking the sizes of the shims & then order some.
     

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  14. Joker

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

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    I have a baggie of 7.48mm shims I can send you some cheap if I have the right sizes. Also have plenty of 3LN spares (including cable outers for the exup if you need) so let me know if you need anything. I need to move some of this stuff on...
     
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  15. downunderfzr

    downunderfzr Active Member

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    Joker PM sent re shims
     
  16. downunderfzr

    downunderfzr Active Member

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    Can't see the pm function Joker - so I pulled out the shims today & these are the shims i need
    2x 1.10
    2x 1.12
    4x 1.22
    Do you have those sizes? I was going to call the local yammie dealer in the morning to see if they have them.
    Cheers
     
  17. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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  18. downunderfzr

    downunderfzr Active Member

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    Finally I had time to tinker, thanks to 'joker' some valve shims were sourced & the clearances are all now in spec.
    So with a warm engine (carbs off) the compression readings were 1) 100 psi 2) 95 psi 3) 105 psi 4) 95 psi.
    The with approx 5ml of engine oil added to each cylinder the readings were all in excess of 160 psi !

    I did have it running again after the valve clearance changes & it did seem to run better but would only start cold after fuel had been squirted into the carbs, once warm it would start without a problem. it is blowing a small amount of grey smoke.

    So I guess the problem has to be ring related & sounds like a tear down will be in order?
     
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  19. kiffsta

    kiffsta Senior Member

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    Grey / white Smoke can mean valve stem seals or head gasket, do you have access to a leak down tester ?
     
  20. Joker

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

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    Ah good work. 160PSI yeh that's a bit of a jump so the likelihood of worn rings is high. The question is - does the smoke settle when the bike is warm and is it little enough to persevere?

    My 3LN3 blew a bit on start up but then it stopped when warm, I'm rebuilding it now so it will get new rings but that's just a question for yourself. To pull the head off and put a new gasket in is $32 and a bit of elbow grease so up to you. Stem seals are a good thing to replace but I personally can't see how they would have a massive impact on your compression readings. It's a pain in the rear to pull all the valves out, very time consuming.
     

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