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Project My 3HX2 FZR

Discussion in 'Your 250cc Projects' started by Miguelone, Nov 1, 2019.

  1. Miguelone

    Miguelone Member Premium Member

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    Well here's my FZR

    For anyone who hasn't seen my introduction thread I picked this up about a month ago.
    [​IMG]
    [​IMG]

    This is how I received it. All the fairings removed and a box of bits and pieces. Thankfully it looks like it's all there.
    [​IMG]
    [​IMG]
    It's possible the K's are genuine. both the tyres are dated the year 2000. PPSR check didn't even come up with any info and after a call to vicroads with them searching the archive found it hasn't seen the road since 2004!

    Overall she's in pretty good shape. There is surface rust all over the frame but nothing terminal. Sometime down the line I'd like to strip it down and really go through it but for the short term I'd like to get everything mechanically sound and get some seat time.

    The bloke I got the bike from hadn't had it very long and told me the guy he got it from had gone through the carbs. After pulling them off though it looks like he did little more than pull them apart, clean and break/lose bits in the process :'(

    Throttle plate for no.1 is bent
    [​IMG]
    Rubber parts are in great condition :confused:
    [​IMG]
    Screws that aren't stripped are just straight up missing
    [​IMG]
    Float bowls full of dirt/grit
    [​IMG]

    Overall a bit of a shtshow.

    No worry though, picked up another set of carbs and a bunch of goodies to help the process along.
    [​IMG]

    Still waiting on some other stuff to arrive but hopefully It'll be running nicely within the next couple of weeks.
     
  2. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    How much were the 2KR intake manifold's, and where are they from ?
     
  3. Miguelone

    Miguelone Member Premium Member

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    They're the Kiwami ones off Yahoo shopping. Though they're absolutely the OEM part in a different bag.
     
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  4. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Looks great. Nice to see one of these rare beasties. If you need them, we have all of the seals and gaskets that go in between the carbs. Then you might be able to save the original carbs as well and keep them as a spare set.
    https://litetek.co/Carb_Kit_Yamaha_FZR250_2KR.html

    A little bit of steel wool on the rusty frame areas and touch up with some spray can will tide you over. Tank is missing cap surround but I guess you are aware of that.
     
    Last edited: Nov 1, 2019
  5. Miguelone

    Miguelone Member Premium Member

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    Have both of your seal kits on the way as well.
    I do have the tank ring as well as the mirrors, rear indicators etc. Once I get it running nicely I'll do a proper clean up and reassemble.
     
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  6. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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  7. Miguelone

    Miguelone Member Premium Member

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    Pulled the carbs apart the other day. Haven't done much more all weekend apart from taking some photos of the toys :D
    2QVFT7R.jpg
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    fYBE4su.jpg
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    ALZKYhw.jpg
    u3iSIxP.jpg
    2hWSgVW.jpg
    As you can probably tell, absolutely love Japanese design and build quality from that mid 80's-mid 90's Bubble economy era.
     
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  8. Miguelone

    Miguelone Member Premium Member

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    Alrighty guess an update is in order.

    So like I'd said I pulled the new carbs down a couple weeks back.
    When they arrived they were crazy gummed up, all the plungers, floats, throttles were stuck solid. Spent some time with the heat gun softening up the varnish until they moved somewhat freely then hit em with some carby cleaner.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    Pulled my old split intakes off and replaced with the nice soft new ones.
    [​IMG]
    [​IMG]
    Good to see the intake ports are all nice and clean.
    [​IMG]
    [​IMG]
    New china fuel pump arrived so that was fitted. The old pump worked but it was very noisy.
    [​IMG]
    [​IMG]

    Pulled the tstat housing to find.. umm...
    [​IMG]
    [​IMG]

    Gross, I cleaned up the thermostat and surprisingly it works fine and the seal is good so I'll reuse that for now.

    Also spent a little time tidying up the original windscreen. It's not 10/10 but a 30 year old piece of plexiglass was never going to be anyway.
    [​IMG]
    [​IMG]

    Finally back to the carbs.
    With the Litetek seals and new diaphragms arrived I set about reassembling after a tonne of cleaning.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    I'm pretty wrapt with how they've turned out. Everything feels perfect and smooth. Worlds away from the old butchered carbs.
    As you may notice in the last pic one of the plungers is missing. Unfortunately the diaphragm was assembled incorrectly which left the plunger on a weird angle. After some back and forth from the seller I've got another one on the way. Pretty frustrating though, just want it running already!!
    [​IMG]
    [​IMG]

    Edit: Almost forgot, was down at the Geelong Revival on Saturday and saw this lovely fizzer in the pits. Unfortunately didn't get to see it race though.
    [​IMG]
     
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  9. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Good job. Should start first touch of the button after all that work.
     
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  10. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Nice work
    Have you removed and cleaned out the radiator and the waterpump and hose's ?
    i've never seen a thermostat housing that gunked up inside

    The Carby diaphram's should be able to rotate on the slide's ?
     
  11. Miguelone

    Miguelone Member Premium Member

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    Yep definitely going to go through the rest of the cooling system. Surprisingly though the tstat housing seems to be the worst part so far. All the pipes and hoses were completely clear.

    Diaphragms definitely don't spin, nor do the original ones. They've got that plastic ring pressing them into place.
     
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  12. Miguelone

    Miguelone Member Premium Member

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    Carried out some more work.
    Cleaned up the tstat housing, got a little carried away with the wire wheel :D
    tGSLDZT.jpg
    Pulled off the waterpump cover for a bit of a look axs well as all the other hoses, pipes and the rad.
    Nothing anywhere near as grotty as the thermostat was fortunately.
    7brI4Iq.jpg
    71L4ahM.jpg
    More excitingly spent Sunday cleaning, stripping most of the bike down to the frame painting and getting to some proper reassembly. I'll get to the swingarm when I get to replacing the chain and tyres.
    kpvqviu.jpg
    kLnf0dc.jpg
    pqEA6sH.jpg
    6a0GG4S.jpg

    Replacement diaphragm has finally landed in Aus too so with any luck I'll have her running before the weekend :D
     
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