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Project First bike, the FZR250 3LN

Discussion in 'Your 250cc Projects' started by I_b_pirate, Feb 17, 2020.

  1. I_b_pirate

    I_b_pirate Member

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    Frames painted, not perfect but doesn't look too bad. Just gonna focus on getting it back together for now, got most of the body work ready for colour just painted with white underfoot for now and stored somewhere safe, gonna work on the suspension next.


    [​IMG]

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  2. I_b_pirate

    I_b_pirate Member

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    One wheel done. Rest of the bike was gonna be too black so think I'll go for the bright wheels so I can be seen better. I'll put the old tyres back on while I'm working on it but they 12 years old so will have to get new ones before she hits the streets.


    [​IMG]

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  3. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    That looks great, a black and yellow colour scheme always looks good
     
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  4. I_b_pirate

    I_b_pirate Member

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    Looks even better with the rubber on her and fitted onto the rear.[​IMG]

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  5. I_b_pirate

    I_b_pirate Member

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    Back on 2 wheels looking fresh. Engines next.


    [​IMG]

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  6. I_b_pirate

    I_b_pirate Member

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    So just did a valve check with the cams in the right place. Intake is within specs but exhaust is too tight. I have watched a video on how to shim them but don't know where to get the shims. if I figure out what's in there atm and what i need I should be able to get them from any bike shop or would I be better sticking with my guy at Yamaha?[​IMG]

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  7. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    You want to remove the cams, and use a magnetic lifter to remove the buckets, then record what thickness shim you've got underneath each bucket - hopefully they have all been installed with the etched number facing upwards otherwise it might be obscured from being in contact with the top of the valve and wearing out

    on this page there's two documents to download to record the values, then it's just simple arithmetic to calculate the reduction in shim thickness required - go to the upper limit of clearance then shuffle whatever you have and work out what you need

    https://www.2fiftycc.com/index.php?threads/fzr250-zeal-fzx250-valve-clearances-howto.1697/

    I believe @kiffsta produced a better version of the clearance recording page somewhere, well I've seen it and I think it's better than mine

    www.precisionshims.com.au is the place to get them, usually order one day and receive them the next
     
  8. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    To accurately measure shims you need an inside micrometer, 0-25mm range, often the numbers printed on top are not totally accurate. They will be 7.48mm OD shims, the same as most jap inline 4's

    With shim and bucket setup, clearance decreases over time due to wear*. Therefore it is ideal to set all clearances to the maximum allowed with the engine cold. Not only does this improve performance, it gives you maximum time between adjustments. If you notice a valve with excessive clearance, it is likely that either the valve stem tip is wearing, or you have carbon/debris on the valve seat.

    *Other systems like Ducati's desmodromic system loosen over time.
     
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  9. I_b_pirate

    I_b_pirate Member

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    Apparently it got new valves when it was torn down. Wouldn't the wear increase the gap over time? So wouldn't it make sense to go for the lower to mid spec?

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  10. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Valve Clearance Sheet
     

    Attached Files:

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  11. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    Valves and seats as they wear - the stem effectively gets longer and the clearance reduces, which is why you need to go to thinner shims to increase the clearance, and especially given that your valves are new, they will seat and that clearance will reduce quickly to begin with - take them to maximum clearance
     
  12. I_b_pirate

    I_b_pirate Member

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    Oh right of course. That makes sense. So I'd wanna go as close to the upper spec and allow the new valves time to seat in properly.

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  13. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Correct.

    After you set the clearances, you should also tune the mixture screws and balance the carbs for optimum performance.
     
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  14. I_b_pirate

    I_b_pirate Member

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    Clearances are all exactly 0.01 below the max tolerances timing is set right and engine is now bolted in. Gotta get exhaust gaskets on Tuesday and new chain and sprokets. In the meantime something electrical and cooling. But progress is being made.
    Big smiles[​IMG]

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  15. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    Sensational work, I was at first a little skeptical that given all of the hassle you had with the engine, that it would drain your enthusiasm and you'd lose the motivation to keep charging with all of the cosmetics

    Very glad I was wrong about that, and to boot, you've got the mechanical elements sorted, so once it's back together it's ride time!!

    :neo::neo::neo:
     
  16. I_b_pirate

    I_b_pirate Member

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    Yeah man, still gotta call up the bike wreckers and see if the can ship me some parts. They over 50km away and still can't travel that far. Mainly need a seat, front guard and the exup cables but I get a feeling I'll have to make them up custom.

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  17. I_b_pirate

    I_b_pirate Member

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    Starting to come together, maybe do a bit of paint over the weekend but got a new chain sprokets and brake pads today as well as some led indicators. Having a bit of trouble routing wires and cables under the cowl does anyone have a pic of the front without the cowl so I can see how it all fits in?[​IMG]

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  18. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    I have my whole front section off and still complete with lights and dash in the frame and cowling ... Ill take some pics t/m
     
  19. I_b_pirate

    I_b_pirate Member

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    Cheers brother much appreciated. Also might have to make up the exup cables. Don't suppose you know what lengths I'd need?

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  20. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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