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Aj's ZXR250a project

Discussion in 'Kawasaki 250cc In-line 4's' started by ajverma, Aug 18, 2011.

  1. ajverma

    ajverma Active Member Premium Member

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    Scratch that, I'm going to seriously consider using a helicoil, and saw your parts on ebay, man that stuff looks smick
     
  2. ajverma

    ajverma Active Member Premium Member

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    Decided I'm definitely not going to do it myself... will leave it to the professionals because one wrong move and the sump is finished, and getting another sump for this bike will just be irritating.. I'll just let it sit with a little bit of a leak, no fairings on anyway, and when I take it for a blue slip I'll leave it with the mechanic to balance the carbies, go over the bike and do the sump bolt then as well, at the moment this is what the bike looks like. I managed with help from the missus to get the wiring loom in and mostly connected up and mount the airbox. Managed to completely strip one bolt in the process, however, there's still another 7 holding it in and this made no difference so I've left it so far.

    The leak over about 5-6 hours: (roughly 3-4 small drops)
    [​IMG]

    [​IMG]
    [​IMG]


    Couple of nicer images I forgot to upload of the frame:
    [​IMG]
    [​IMG]
     
  3. Slender

    Slender Well-Known Member Premium Member

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    man i love the look of those USD forks. looks really good mate u should be proud.
     
  4. PD186

    PD186 Member Premium Member

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    Hi AJ
    If you have stripped out where a bolt goes in you can get a thread repair kit from your local bearing supplier Look up CBC ect. the kit will cost a bit but you just get new inserts when needed you don't need to replace the whole kit. If you intend to do more work on bikes it is a good investment.
     
  5. Phil

    Phil Senior Member Contributing Member

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    Hey AJ
    Bike is looking good, if you are concerned about your sump plug let me know as I am rebuilding Chris's bike and I have an engine with a sump on it. You don't need to remove the engine, simply drain the oil and remove the old sump, problem solved.
    Over to you Amigo.           
                                                            Cheers  Phil
     
  6. ajverma

    ajverma Active Member Premium Member

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    Thanks very much mate I appreciate it! Yeah I love the look of the forks, the black stanchions really make it look right!

    This would be the helicoil I assume? If yes, I am planning to go that way or another... soon! :D

    Hey Phil,

    If you had that sump handy, I could send you the one I have now in trade with some cash on top, for your sump? How's that sound? I'm willing to do it if you are, I already asked Chris for a couple of parts that I'm looking at modifying, I'd really love a rear subframe to play with and the tank bracket (my bike was missing one!) so I can get it all together. How does this sound? If I can get that organised, I'm ready to pay you asap.

    Thanks heaps Phil,

    Aj
     
  7. ajverma

    ajverma Active Member Premium Member

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    Hey guys, today I managed to get all the ancillaries connected up, I turned the bike on, HEADLIGHTS WORK! WOOOO! Know something has been done right, however, the bike doesn't turn over at all, I connected up the throttle case to try turn it on....

    1. put key in ignition and turn it
    2. success, lights come on and neutral indicator and oil light are on, things are going well
    3. flip the kill switch to on
    4. expecting it to turn over on the starter
    5. press starter
    6. nothing but silence
    7. DAMN IT!

    Anyone have any point of reference? What should I be checking, in order? [battery is fine, but the starter isn't even turning over, and I'm pretty sure everything is connected up...
     
  8. kiffsta

    kiffsta Senior Member

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    Hey Aj, Have you made sure the earth is connected from the harness to the motor, the staerter motor should have a 12v feed from the stater solonoid \ relay, then I guess its checking fuses etc. Id also check the netrual switch is hooked up and displaying green on the dash. Do you need to have the clutch in the alloow the strater to be pressed?
     

    Attached Files:

  9. ajverma

    ajverma Active Member Premium Member

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    ahhh yeah I've done all those things, Didn't realise that this bike needs the clutch in to start, I thought it'd at least turn over on neutral... hmm... Will check it out today! Thanks Chris!
     
  10. ajverma

    ajverma Active Member Premium Member

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    YES!!!!!!!!!!!!!!! turns out the clutch lever does have a switch! I connected it up and she turned over easily!!!! YEAHHH!!!!!!! Will get a video today and upload!
     
  11. kiffsta

    kiffsta Senior Member

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    WooHoo, sometimes its the simple things..  you can disable that switch too !!!

    Chris
     
  12. ajverma

    ajverma Active Member Premium Member

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    Yeah I think I'll do that! It's not too bad though, I don't have to have the clutch pulled in or anything, I just need to have the left switch block connected up.

    on another note:

    Damn it, got it running well and everything, came out this morning and there are two new oil leaks, one from just above the stator cover and one from just above two of the extractors... wtf! Managed to fix the extractor one mostly, but the one from the stator cover is brand new and I have no idea where it's coming from!

    the worst thing is, the only part I haven't worked on for this bike, is giving me problems... all I did to the engine was paint it and replace oil filter/sparks and oil, the mechanic did the valve clearances, think they didn't put the head on correctly? I think this is ridiculous, 3 leaks from this engine, and I haven't done anything, and this new leak above the stator cover is just seeping oil constantly and I have no idea why
     
  13. kiffsta

    kiffsta Senior Member

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  14. ajverma

    ajverma Active Member Premium Member

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    Hey Chris,

    This is where the leak is coming from:

    [​IMG]

    It's around that bolt in the middle and there was nothing yesterday when I was running the bike, but this morning there were a few drops on the ground and my stator cover has lots of oil on it... WTF!!!

    There's a hole just above the headers, two of them are leaking damn it!


    Well here's the first time she started anyway:

    [​IMG]
     
  15. Slender

    Slender Well-Known Member Premium Member

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    That sounds tough man. Very clean looking too. Hurry up and finish so we can all see it LOL :Thumbs_up:
     
  16. kiffsta

    kiffsta Senior Member

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    that bolt is one that holds the stator cover on  isnt it ?  Get a new seal (see above) or some gasket goo

    Chris
     
  17. ajverma

    ajverma Active Member Premium Member

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    yeah I've got gasket goo, I'll give that a go on Sunday, I don't want to do this at night... anyway

    Well guys, all things aside, I think the bike is turning out pretty good, I'm just getting upset over small things, that mechanic just let me down, and this is just making me distrust them even more. Here's some media, what do you reckon, do you like it? :)

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
  18. ajverma

    ajverma Active Member Premium Member

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    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    The fruits of my labour are starting to bloom, I'm pretty happy with the progress now
     
  19. kiffsta

    kiffsta Senior Member

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    nice stickers Aj, what are you doing for an exhaust...  i have a good one for sale, just ask Slender
     
  20. ajverma

    ajverma Active Member Premium Member

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    Hahah thanks mate,

    Is there a brand on it? Is it a stock exhaust? I'm looking for something cheap because I'm going to chop it in half... Do you think you could organise for those items for me Chris? I'll be heaps happy if you can send me a sump/can and the battery bracket, I'm pretty much useless without them!
     

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