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Im trying something new - my ZXR250

Discussion in 'Kawasaki 250cc In-line 4's' started by Tim_, Mar 22, 2014.

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  1. risky

    risky risky

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    before you paint give it a wipe with wax and grease remover and then wipe with a tack rag.
     
    risky, Apr 5, 2014
    #81
  2. Tim_

    Tim_ resident nutcase Contributing Member Dirty Wheel Club

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    image.jpg
    And here is a picture of my garage after all that. Yep it's a mess but I don't care. Hahaha.
     
    Tim_, Apr 5, 2014
    #82
  3. risky

    risky risky

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    compared to my garage that i cannot fit a bike in that is magic.
     
    risky, Apr 5, 2014
    #83
  4. Tim_

    Tim_ resident nutcase Contributing Member Dirty Wheel Club

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    This time I won't worry. This is just to touch up the nose. So it's all black instead of patchy red and black. I am actually taking the whole fairing to a friend and getting it gloss black. And the wheels will get plasti dipped black too.
     
    Tim_, Apr 5, 2014
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  5. Tim_

    Tim_ resident nutcase Contributing Member Dirty Wheel Club

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    3mini bikes and 3 roadbike sand I want more. Haha
     
    Tim_, Apr 5, 2014
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  6. Tim_

    Tim_ resident nutcase Contributing Member Dirty Wheel Club

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    This is why being mates with the maintenance guys at work pays off.

    All those rusted in bolts are gonna be replace with food grade stainless steel Allen key bolts.

    image.jpg
     
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    Tim_, Apr 6, 2014
    #86
  7. Tim_

    Tim_ resident nutcase Contributing Member Dirty Wheel Club

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    image.jpg image.jpg
    Before and after a quick pressure pack spray to cover up the red. Until I get the fairing painted properly that is.
     
    Tim_, Apr 6, 2014
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  8. risky

    risky risky

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    i have found dulux cans give a better finish than the cheapies.some cans sold in auto spares places are not for vehicle use! most cans are not enamel but a varnish.the real cheapies are so thin there is little coverage.
     
    risky, Apr 6, 2014
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  9. Tim_

    Tim_ resident nutcase Contributing Member Dirty Wheel Club

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    image.jpg image.jpg
    I figured seeings how I only really need to do the front breaks and a carbi tune I could put the fairing back on. Well for now.
    My plan is once it's all running a1. I'm striping it back to the frame so I can clean everything. Because I noticed there is a lot of oil and dirt and grime in tight spots you could only get to by taking it apart.

    I like how the over sized stainless bolts turned out. Gives the bike and industrial look.
     
    • Like Like x 4
    Last edited by a moderator: Apr 6, 2014
    Tim_, Apr 6, 2014
    #89
  10. risky

    risky risky

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    ct18 truck wash is good for cleaning. spray on ,leave and waterblast off. leaves clean. i also use dishwashing liquid and it takes road grime off rims.
     
    risky, Apr 6, 2014
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  11. Tim_

    Tim_ resident nutcase Contributing Member Dirty Wheel Club

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    Cheers mate will keep it in mind. I will be rubbing all the steel down with a green scrubbing pad to get that grain finish back into all the steel.
     
    Tim_, Apr 6, 2014
    #91
  12. Tim_

    Tim_ resident nutcase Contributing Member Dirty Wheel Club

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    Ok so I have a question. I went to go start my bike after work. And it was like the battery was dead. It wouldn't turn the starter motor. It was like something was stopping it. I pressed the start button a couple of times and it finally started winding over. But there was no spark. Not tell tail put put put out the exhaust of it trying to start. Just winding.

    So I twisted the fuel tap to prime then back to res. after a minute or 2 and me panicking. It struggled but eventually started. That's when I noticed it didn't sound properly. Now could something cause it not to fire on all pistons when it's cold? Because once I raised the revs it sounded like it should. But once the revs dropped and the bike warned up I sprayed the headers and only the #1 and #4 header pipes were hot. So now I'm getting confused as to why it it's doing this. Gasket seals? Maybe? Or valves?
     
    Tim_, Apr 7, 2014
    #92
  13. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    1 coil sparks 1 and 4 and the other 2 and 3 .... start there ..... swap them around and see if 2 and 3 fire
     
    GreyImport, Apr 7, 2014
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  14. risky

    risky risky

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    likely corroded connection to or a dead coil
     
    risky, Apr 7, 2014
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  15. Tim_

    Tim_ resident nutcase Contributing Member Dirty Wheel Club

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    Pot 2 is sparking. I swapped them all around and it won't even kick over. Wouldn't the firing sequence be all out of whack now?
     
    Tim_, Apr 7, 2014
    #95
  16. DougFella

    DougFella Well-Known Member Premium Member Contributing Member

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    On an A model firing sequence is different, left to right (from a sitting on bike position looking down) coil 1 cylinder 1 and 2, coil 2 cylinder 3 and 4. I will double check this for you when I get home but I had this confusion when i was rebuilding my one.
     
    DougFella, Apr 7, 2014
    #96
  17. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Its the same on the ZXRs and the FZRs

    Heres the A model schematic....

    a mod coils.jpg
     
    GreyImport, Apr 7, 2014
    #97
  18. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Tim ...start by checking all the caps ...unscrew them and look inside both ends for corrosion.
    Snip a few mms off the ends of the leads to give the cap some new shiny wire to bite into ...make sure the screw goes into the wire not the rubber .

    Connect them as above ...then take out 1 plug at a time , put it back into the cap/lead and lay it on the head .....turn the motor and look for a nice bluey spark.
    rinse and repeat

    If theres failures next step is to test the coils with a multimeter

    Are the plugs actually new?
     
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    GreyImport, Apr 7, 2014
    #98
  19. DougFella

    DougFella Well-Known Member Premium Member Contributing Member

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    Go with Grey's schematic. I may be going crazy because it was about 6 months ago since I did concerted work on my ZXR but for some reason I think I had the 1,2,3,4 setup... I'll look later on.
     
    DougFella, Apr 7, 2014
    #99
  20. Tim_

    Tim_ resident nutcase Contributing Member Dirty Wheel Club

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    Plugs are new. I'm thoroughly confused by this now. Ok so it the proper order. Cylinder 2 and 3 headers rub cold. When I swap around the 1 and 2 lead cylinder 3 header will be hot but 1 and 2 are cold. I swapped it back now but am going to snip the end as I noticed they are very loose. So I'm thinking it's a circuit not connecting somewhere.
     
    Tim_, Apr 7, 2014
    #100
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