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Help Balius ZR-2 engine rebuild

Discussion in 'Kawasaki 250cc In-line 4's' started by Rocky, Mar 2, 2018.

  1. Rocky

    Rocky Active Member Premium Member Contributing Member

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    Hi All

    New to this hope you all doing fantastic!! I just bought a 94 Balius been standing for about 5 years. I got it started but has a scary loud knock when bringing the revs to about 6k and up, and got a serious amount of white smoke even at idle. I did not have the bike running long prob about 10 min at most. I am assuming a engine rebuild is in the near future? Is it ok to follow the ZXR250,s engine specs for a safe rebuild of the engine?

    Also about buying parts where can I look online preferably as I am I live in china.

    Thanks guys have a good one!!
     
  2. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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  3. my67xr

    my67xr Senior Member Staff Member Premium Member Contributing Member

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    Theres a lot of parts on aliexpress, try to find engine parts from AHL they have good feedback
     
    Last edited: Mar 2, 2018
  4. Rocky

    Rocky Active Member Premium Member Contributing Member

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    Actually I checked the bike had oil in yes but to be honest I didn't try to see how its looking nor change it. I did some cleaning on the bike over the weekend pulled out the plugs found it had 3 different types of plugs 2 of them for scooters I believe (NGK C7HSA) a lot shorter than the original spec. I will change the oil and filter over the next few days. What oil is suggested?
     
  5. Rocky

    Rocky Active Member Premium Member Contributing Member

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    Ok Ill check it out thank you
     
  6. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Give caltex delo 400 a go. $50 for 5L at caltex servos
     
  7. Rocky

    Rocky Active Member Premium Member Contributing Member

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    Thanks for the advise Linkin let me see if I can find it.. had a quick browse we just seem to get it in 18-200L in china hahaha but I'm I will find a 5L somewhere.
     
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  8. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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    This one ... we use it in the bikes and I use it in my petrol Land Cruiser ... its multifleet

    delo 400.jpeg
     
  9. Rocky

    Rocky Active Member Premium Member Contributing Member

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    Ye found that one thanks guys!
     
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  10. Rocky

    Rocky Active Member Premium Member Contributing Member

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    Good Morning all
    So spent the weekend going at the balius again changed the oil , oil filter , spark plugs and air filter ( as it didn't have one) after hours and a few jump starts I finally got the bike started. the bike has a rattle on the bottom end not sure if this could have something to do wit the oil pump. the bike is still smoking as well.

    I also really struggle to get the bike started. the engine always sound like it wants to catch but just doesn't I feel like I'm very lucky when the bike actually fires up.

    Any suggestion on troubleshoots I can start looking at.

    Appreciate any help. Thanks:)
     
  11. Rocky

    Rocky Active Member Premium Member Contributing Member

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  12. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    If it is hard to start then it Could be that your valve clearances are out
     
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  13. Frankster

    Frankster See the World before you leave it Staff Member Premium Member Ride and Events Crew

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    My first instinct with any new bike is to do a Compression Test and then check for spark and then check fuel. @kiffsta is right about valve clearances causing poor starting, but I'd check the basics before you start pulling the engine apart. That "bottom end knock" needs to be diagnosed too. No knock is ever good. You can check the bottom end without taking the engine out, but if you take the engine out you can accomplish a lot. It looks like you have plenty of room to work, that's a good thing. Good luck Rocky.
     
  14. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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    My FZR had a terrible knock after I had let it sit with no oil in it at all for a long period but couldnt figure out how it had suddenly happened as it was fine before I had it sitting while doing the clutch etc ..... after I ran if for a bit it slowly got less and less and I put it down to lack of lubrication and eventually when it circulated enough it was fine and has been ever since

    Same with the smoke .... a few revs in the driveway is pretty much meaningless ... a few Ks out on the road under load gives a much better indication of where its at
     
  15. Rocky

    Rocky Active Member Premium Member Contributing Member

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    Hi All

    Thanks for the advice. @Frankster so I have done and gone thru the spark and fuel its a check on those. I have just bought a compression tester as soon as it arrives I will do the test. I have heard the ZXR250 engine is pretty much the same? so I will be following the steps in the service manual.

    @GreyImport thanks for that message you have given me some hope and excitement I hope this could be the issue their:D. Once I have done what Frankster suggested I will take it around the block see how it goes.

    @kiffsta thanks for the info we will see what the future holds.
     
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  16. Frankster

    Frankster See the World before you leave it Staff Member Premium Member Ride and Events Crew

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    Rocky, Balius engine has the same bore and stroke as the ZXR250C engine (49.0 x 33.1), but it has to be different as the HP is a lot less than the ZXR. I would guess the CDI is different as I think the Balius redline is 16,000rpm. Cams might be a bit different too. Ask questions here if you're not sure. Cheers Frank
    Balius Spec 1.jpg Balius Spec 2.jpg Balius Spec 3.jpg
     
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  17. Rocky

    Rocky Active Member Premium Member Contributing Member

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    Hi Frank

    Ok thanks so much I Believe the Blasius relines at 19k this is the info I have found that's is matching my frame number sequence.

    Screenshot (21).png Screenshot (22).png

    My Frame number matching the ZR250A4 model. but I will def be asking more question as my build goes along. I am truly thankful for this site.

    Have a good one!
     
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  18. Frankster

    Frankster See the World before you leave it Staff Member Premium Member Ride and Events Crew

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    That's interesting information you've posted Rocky. The info on my post is from a Balius (A7) Owner's Manual printed in Japan. The spec from bikeswiki.com would suggest this bike (A7) has 40hp @ 15,000rpm. I've never owned a Balius, but I'm almost certain they never had the ZXR250A engine (45hp@15,000) in them. That spec sheet seems to be grouping ZXR250 and Balius bikes together. The 48.0 x 34.5 bore and stroke engine was only ever available in the ZXR250A bikes. It makes 45hp at 15,000rpm, whereas the ZXR250C engine makes it's 45hp at 15,500rpm. Also, I always thought the Balius engine had 39.5hp. The fact the Owner's Manual claims it is 26HP was a surprise to me. Anyone else out there have an Australian Balius to confirm those figues? Since Rocky's bike is an overseas job, there may be some versions/specs that differ from Aussie delivered bikes.
    Balius Manual.jpg
     

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