Custom/restoration FZR250R-R

Well guys, I've owned this FZR since 2003 but it's been off the road pretty much the whole time. I think it's been ridden a total of about a year max the whole time I've owned it. Last November a friend and I were having a beer in my garage and decided to pull it to pieces. That's when this final rebuild began and why I decided to do it properly.

This is what it looked like when I first bought it. Such a nice looking bike huh? <!-- s --><img src="{SMILIES_PATH}/icon_biggrin.gif" alt="" title="Very Happy" /><!-- s -->


So far the list of modifications is relatively short. The large majority of time has been spent cleaning, sanding, painting, polishing, etc, to get it looking like somebody had put a lot of effort into it <!-- s --><img src="{SMILIES_PATH}/icon_cool.gif" alt="" title="Cool" /><!-- s --> ...which they have of course haha.

Modifications:
- ZXR250A complete front end conversion
- ZXR250C front guard
- FZR400RR-SP CNC Billet SES Race-products rearsets
- FZR400RR CNC Racing fuel cap
- 2004 GSX-R600/750 front master-cylinder and clutch perch
- Black CNC Billet racing adjustable brake and clutch levers
- Buell XB12 switch gear and throttle/grips
- FZR400RR Carbies
- Heavy duty clutch kit + new fibres and steels
- Complete gearbox and cylinder head overhaul
- Barrels bored to fit new .5mm oversized pistons
- All engine cover bolts replaced with stainless steel items

Here's some pictures to show you guys my bike and where it's at right now...

Frame and swingarm powder-coated in flat black. First test fit of the front end.


Engine out for a spruce up <!-- s --><img src="{SMILIES_PATH}/icon_smile.gif" alt="" title="Smile" /><!-- s -->







Back on two wheels again and outside for some sunshine haha


Wheels freshly powdercoated in red (they look orange in some shots coz of the flash <!-- s --><img src="{SMILIES_PATH}/icon_sad.gif" alt="" title="Sad" /><!-- s --> ) with sweet new wavy rotors fitted





New rearsets and fuel cap <!-- s --><img src="{SMILIES_PATH}/icon_cool.gif" alt="" title="Cool" /><!-- s -->



Engine all finished and back in the bike (yusssssssss!)











So thats my project so far. Thats as much as ive managed to do so far with my meagre budget (only the wife is working right now <!-- s --><img src="{SMILIES_PATH}/icon_redface.gif" alt="" title="Embarassed" /><!-- s --> ) but i hope to get the exhaust fab started over the next few weeks and hopefully in a presentable state by the end of September at the latest. When I first started to pull this thing apart it was going to have a turbo fitted and im still deciding whether i want to finish that (got as far as fitting the turbo and starting the plumbing/intake plenum) or whether i just want to get her back together and charging away as she was originally intended to. The subframe is only on there for me to fit the tank to and so ive got something to work with/measure/cut-up as i make a new subframe to fit a new tailpiece. I had a 2003 R1 tailpiece that i was going to fit but it turned up in the post and is as wide as the fricken planet so i think im going to end up fitting the Honda RS125 tailpiece I had originally intended to.

Any feedback from you guys on what you think of the bike so far and what you think i could improve/add as i go along will be greatly appreciated. I love hearing what other riders think as we're all so different, but so similar at the same time. Here's a parting shot of me on my baby to leave you with <!-- s --><img src="{SMILIES_PATH}/icon_cool.gif" alt="" title="Cool" /><!-- s -->

 

Thanks dude, im glad you like it. I love the red and black too, i think i got the contrast just right so far. Its quite hard to get the balance right i think between too much black and not enough colour. So far ive spent about $1500 on it including paint, gaskets, etc. I have a friend that does powder-coating so im fortunate that i get that done super cheap.

 

Haha, yea the front end was fully restored before i had the idea to replace it. All new bushes, caliper seals, pistons, etc. Was immaculate. Sold it to a FZR rider in Auckland for $200 coz nobody wanted it. Well nobody here anyways. I wish id thought to join this forum and list em up back then. Woulda sold like hot cakes.

Nah, about 6months into my ownership i was at a party and a drunk friend (i use the term loosely) stole my keys outta my lid and took it for a joy ride. Considering how drunk he was im surprised how lightly (again, i use the term loosely) he damaged it. The fairings were pretty much toast so i took em off to do a naked. Ive still got the complete triple tree with fat-bar mounts and fat bar if anyones interested? Ive always planned on a nicer tail unit but now im considering putting 3LN5 front fairings on. Theyre just so sexc <!-- s --><img src="{SMILIES_PATH}/icon_biggrin.gif" alt="" title="Very Happy" /><!-- s -->

 

These are standard size fat-bars for a motocross bike fitted to a standard 3LN triple-clamp. They've got a few scratches here and there but they're in generally good condition. I have no idea if they'll fit a 2KR but im sure you could find out on here.

Does anybody know if 3LN triples fit 2KR models?

 

I dont think i understand? These are bolted directly to the top triple clamp via 12mm bolts with lock-nuts and compression washers. The underside of the triple has been drilled at two structural cross-sections to increase torsional strength and reduce any possible flex the new holes might create. It doesnt get any stronger than this, but i understand if you arent comfortable with somebody else's custom work. I prefer to do my own custom work, probably for the same reasons. If i do it, i know it's strong enough <!-- s --><img src="{SMILIES_PATH}/icon_biggrin.gif" alt="" title="Very Happy" /><!-- s --> I only took them off because i wanted to go back to the tucked-in under fairings look <!-- s --><img src="{SMILIES_PATH}/icon_cool.gif" alt="" title="Cool" /><!-- s -->

Havent really done anything new yet. Painted the rear master cylinder which i think looks wicked cool. What do you think? <!-- s --><img src="{SMILIES_PATH}/icon_cool.gif" alt="" title="Cool" /><!-- s -->

 

Master cylinder is the correct terminology. A slave cylinder is used at the end of a hydraulic system to magnify the pressure change made by the master cylinder. Road bikes only have a master cylinder on each brake, front and rear. Some quads run slave cylinders on each wheel though.

I like the scotchpad on the die grinder idea. Probly a lot less fiddly than pissing around with a blade <!-- s:???: --><img src="{SMILIES_PATH}/icon_confused.gif" alt=":???:" title="Confused" /><!-- s:???: -->

 

Ive never actually thought of a caliper as being a slave-cylinder, but now that you point it out its blaringly obvious. My assumption has always been that there just simply isnt one and that the master-cylinder is all that was required. Makes more sense when you note that the slaves on quads are only there to operate the drums.

<!-- s --><img src="{SMILIES_PATH}/icon_biggrin.gif" alt="" title="Very Happy" /><!-- s --> See, you do learn new stuff every day <!-- s --><img src="{SMILIES_PATH}/icon_smile.gif" alt="" title="Smile" /><!-- s -->