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Project Little ZXR250 project

Discussion in 'Your 250cc Projects' started by pete05, Jan 4, 2020.

  1. pete05

    pete05 Member Premium Member

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    Hey all,

    I just recently picked up this little zxr250 from FB market place to do as a project with my 13 year old son.
    The bike was last registered in 2012 and is in rough shape.
    After not being run since 2012 I have managed to get it started and have run it up to operating temperature twice.
    The carbys have been off for a clean out but need every seal replaced.
    Brakes don't work and tyres are shot. Fork seal are not leaking to my surprise but I will service them anyway.
    I will be stripping this one to a bare frame in the next few weeks, for a repaint and rebuild.
    IMG_5619.JPG IMG_5620.JPG IMG_5621.JPG IMG_5622.JPG IMG_5624.JPG IMG_5626.JPG IMG_5630.JPG IMG_5642.JPG
     
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  2. pete05

    pete05 Member Premium Member

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    So another day on the zxr250 and some good progress, I have discussed colours with my son and at this point the frame will be matt black and the wheels are staying white, fairing colour is still undecided, I have a few ideas we will see how it plays out.
    Only a few surprises, found the left foot peg mounting is bent and the key barrel mount is broken, other than that the tear down went well.
    20200105_125859.jpg 20200105_125912.jpg 20200105_125918.jpg 20200105_131709.jpg 20200105_131712.jpg 20200105_131717.jpg
     
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  3. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  4. pete05

    pete05 Member Premium Member

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    Thanks, I have read all of your thread yesterday, you have done a nice job on yours.
     
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  5. pete05

    pete05 Member Premium Member

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    More progress over the last few weeks, I have spent many hours paint stripping, cleaning and painting.
    20200109_124128.jpg 20200125_134936.jpg

    All the swing arm bearings are in good condition as are the triple clamp bearings, I would say at one point this has been gone over by a previous owner, everything was well greased when I pulled it apart so its a bonus not to have to replace many of the bearings, though I will be doing wheel bearings once I work out how to get them out without a special puller.
    20200110_173257.jpg
    Header has been cleaned up with a flap disc and wire wheel and paint in exhaust paint, geez it looks so much better.
    20200111_104954.jpg 20200112_143145.jpg

    I have done some testing on the wheels and they are definitely powder coated so I am leaving them white and have given them a cut back with some compound followed up with a good coat of wax, the date code on the current tyres is from 2002 so they will be getting the flick and at this stage I'm thinking some Dunlop alpha 14 should work nicely.

    I have ordered the litetek seal kit for the carbys so once that arrives they will get a full rebuild.

    Also I have been looking to replace the rear shock, it seems the yamaha r6 unit is the go so I will keep an eye out for a decent one at a fair price.

    Should be more updates to come soon.

    What weight oil are people going for with the front forks?
     
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  6. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    My Bike:
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    I changed the rear wheel and sprocket carrier bearings as the front were ok , on my ZXR

    This is a link to my post on it .... the secret is to shift the axle tube sideways so u can just tap the bearings out from 'behind' thru the hub ... from memory it looked like u can use the same method for the front
    sprocket carrier has a circlip
    Also u need to be careful to not completely seat one of the rear wheel bearings as then the sprocket carrier doesnt sit "in'' the wheel hub correctly .... theres a line in the hub that marks where the bearing is supposed to sit ... if that makes sense ... if you look closely before u take everything apart/out, u will see what I mean ... bit hard to explain

    https://2fiftycc.com/index.php?thre...odel-stealth-edition.1949/page-12#post-125890
     
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  7. pete05

    pete05 Member Premium Member

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    Thanks I will have look at shifting the axle tube, I have done the sprocket carrier bearing already, I will have a go at the rear bearings tomorrow with any luck.
    We have two 40deg + days in Penrith over the weekend so not sure how much progress I will make in the shed, I had originally planned to repaint the lower fork legs but not the most ideal weather for it.
     
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  8. pete05

    pete05 Member Premium Member

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    My Bike:
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    Well it's finally a roller again, new wheel bearings front and rear, all suspension bearings cleaned and serviced, forks stripped and cleaned with fresh 10wt oil and a trial fit of the new rear shock.
    My seal kit turned up for the carbs so they are up on the bench next for a rebuild.

    20200218_162654.jpg
    20200218_162702.jpg
    Front discs cleaned up and repainted

    20200218_162721.jpg
    New rear shock in for trial fit.

    20200218_162728.jpg
    White wheels polished up ok, disc cleaned and painted, it is under size so will need to source a new one at some point.



    20200218_183551.jpg
    These will be going in the ultra sonic cleaner at work. I have a few broken airbox screws to try and remove, I hope they will come out fairly easy after a stint in the cleaner.
     
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  9. pete05

    pete05 Member Premium Member

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    My Bike:
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    What are peoples thoughts on tyres for these bikes, looking at either the alpha 14 or gpr300?
     
  10. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Alpha 14's are the best sticky tyre you can get, but I'd go with GPR300's for commuting.
     
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  11. pete05

    pete05 Member Premium Member

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    Thanks, no plans for any commuting just fun social rides with mates and some track days at Luddenham raceway.
     
  12. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Alpha 14's then, no doubt.
     
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  13. crshbndct

    crshbndct Member Premium Member

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  14. pete05

    pete05 Member Premium Member

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    2008 Yamaha r6
     
  15. crshbndct

    crshbndct Member Premium Member

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    What did you have to do to make it fit?

    Sent from my Electric Toothbrush using Tapatalk
     
  16. pete05

    pete05 Member Premium Member

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    I will go over that in future posts with some more details on what I do, the bottom of the shock is basically bolt in, the top of the shock is different in that the Yamaha uses a smaller diameter bolt, the two bushes in the frame for the factory shock need to be replaced with ones that are a smaller internal diameter for the r6 shock bolt. I have read of some guys drilling out the r6 shock to suit the larger bolt but haven't fully investigated this yet.
    Its a good cheap upgrade that's fully adjustable, I picked mine up for $120. My stock shock had rust on the chrome shaft, which was going to destroy the seal.
     
  17. crshbndct

    crshbndct Member Premium Member

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    Awesome, thanks for the reply. I imagine making up an impregnated polyurethane bushing won't be too difficult.

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  18. pete05

    pete05 Member Premium Member

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    The bushing in the frame will be out of mild steel as the shock already has a rubber mount in the top end.
     
  19. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  20. pete05

    pete05 Member Premium Member

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    Just going through the carb rebuild and my idle mixture screws had no o rings or washers can someone confirm the washer goes against the spring and the o ring is last to go on the needle?
     

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