This one I picked up for a kiffsta price It is a 1992 ZXR250 C2, built and imported from Japan. Here it is next to my Malaysian one: Paint job is matt black on the fairings so picks up marks easily... but the tank looks a bit nicer It has the usual wear and tear of an old grey import learner bike - thrashed about with little more than the bare minimum maintenance (or less than that), and any problems are fixed by the most ham-fisted means possible. This bike has a bent handlebar, missing mirror bolts, leaky fork seal, missing retention mechanism for the pillion seat, no tool kit, a lithium battery that is too small, aftermarket exhaust that was installed by hercules resulting in a bent flange mount and no doubt other shite that I have yet to find under the covers... But for now, all that and more are the least of my worries with this bike... the showstopper revealed itself after running the bike up for a bit: The selector shaft is leaking pretty badly. As for the cause, the chain seems on the tight side, but not too tight. It is dry and rusty after all. In any case, I started the bike and ran it up... a bit smokey, pilots a bit clogged at first but cleared up and idled. Motor sounds good. Carbs appear balanced as throttle response is better than my silver one. Has a hanging idle so probably air leaks to investigate. So... now there is the dilemma of what to do with the bike. I could fix the problems and use it as a track bike. I could keep it and pinch parts off it as needed. I could part it out and put cash towards fixing up my silver one... decisions decisions... Would like to hear your thoughts concerning the selector shaft, too.
Sounds like a plan. Hopefully I will get away with just a replacement seal Had a look at the service manual and it doesn't mention any bearing for the selector shaft.
Did u look in here? https://www.2fiftycc.com/index.php?resources/kawasaki-zx250-zxr250-zxr250r-c1-parts-schematics.137/
Yeah, its not clear though... might be a bearing behind the seal and another on the right hand side past the selector fork bits 92051 in the 2nd pic appears to be the seal Should be happy days for me then
No bearing. I would pull the shaft out, too tricky to get the seal out and in with the shaft in, but that is just my two cents. Grab a new clutch cover gasket before you start.
Does the shaft run through to the clutch side though? To me it looks like it's contained within the gearbox section of the cases. The diagrams are not to scale with each other. Can the shaft be pulled and replaced without splitting the motor?
if you're careful you can use self tapping screws into the oil seal to get a hold to extract it - for clearance you may need to make the heads on the screws smaller - put them into a drill and buzz heads with a grinder, otherwise it should be easily accomplished with 2 or 3 screws
Yes, you need to remove the clutch basket & oil pump shaft to get to the shift shaft, if it cant be pried out externally. Part # 92051-005 common part from Kawasaki
OK so a little bit of movement on this project. New right handlebar arrived today, fork seals on the way, have 2 clutch gaskets and I ordered 4 gear selector oil seals (part 92051-005) since they were cheap. If anyone needs one, let me know.
I gave this bike some attention today. Topped up the oil, got some fresh fuel plus stabiliser in the tank, and fired it up. Reluctant to start from old fuel, but once the new stuff was flowing it ran well. In fact, it runs better than my silver one. It rattles less, idles better and feels smoother on the handlebars. I warmed it up properly and the smoke from the exhaust has mostly cleared. Bike needs a good run to see for sure though, but not before the oil leaks are fixed.
Maybe check the torque settings of the engine mounting bolts on the silver zxr, & if all mounting lugs are in place, the motor I removed recently was done up that tight it was pulling in the frame. Try swapping the carbies over & see if the silver zxr runs any better with the other carbs.
That's a good idea as the silver bike has had an engine change in its life. All my tools are at work so I'll have to do it there. But after my trouble with the carb boot clamps, no f#$%^ing way I'm taking carbies off again. They need syncing for sure though