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My ZXR250A Project Log

Discussion in 'Kawasaki 250cc In-line 4's' started by DougFella, Apr 28, 2013.

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  1. DougFella

    DougFella Well-Known Member Premium Member Contributing Member

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    You champ, I used Brian last time but have been struggling for days to remember his name. Cheers!
     
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    DougFella, Aug 6, 2015
    #121
  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Good stuff Doug :thumb_ups:
     
    GreyImport, Aug 6, 2015
    #122
  3. DougFella

    DougFella Well-Known Member Premium Member Contributing Member

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    Woohoo bike is back together!

    The electrical issues were being caused by a faulty indicator relay. Replaced it with a spare one, rear lights and blinkers all work again.

    There was a leak coming from the radiator drain bolt. Replaced bolt and washer and seems to be ok now.

    went for a quick ride round the yard and seems to be going well! A short sneaky test ride this arvo some time and all going well book in for a road worthy this week.

    Fingers crossed

    Sent from my SM-G900I using Tapatalk
     
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    DougFella, Aug 8, 2015
    #123
  4. Phil

    Phil Senior Member Contributing Member

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    Great news Doug, sounds like it's coming together. A roadworthy and a quick prayer to the weather God's with hope that the mercury starts heading in an upward direction. Time to hit the road. Next week a ride is on.....no better way to test the bike out,
    something to think about. Time to enjoy the fruits of your labour :thumb_ups:
     
    Phil, Aug 8, 2015
    #124
  5. DougFella

    DougFella Well-Known Member Premium Member Contributing Member

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    Yea i would love to make that ride.

    Afternoon test ride showed up a few glitches though. Got a hesitation between 4-8k and 10k plus rpm. Given up for the day will do some "troubleshooting" tomorrow

    Sent from my SM-G900I using Tapatalk
     
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    DougFella, Aug 8, 2015
    #125
  6. DougFella

    DougFella Well-Known Member Premium Member Contributing Member

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    Hey guys I am tracking down either a vacuum leak or an issue with the carbies. Can someone clarify what I should be doing with this vacuum lead running from the carbs.
    2015-08-09 16.09.50.jpg
    In the C model it would go to a Vacuum valve, but no vacuum valve on the A model. Should I leave it open to air, or block it off.
     
    DougFella, Aug 9, 2015
    #126
  7. kiffsta

    kiffsta Senior Member

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    On top of the airbox, near the rear, it folds over the top then plugs in
     
    kiffsta, Aug 9, 2015
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  8. DougFella

    DougFella Well-Known Member Premium Member Contributing Member

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    Do you mean plug it into the small hole there?

    A mechanic a while ago plugged that hole and taped the tube to the top of the box (open to air). Maybe that's causing the issue?
     
    DougFella, Aug 9, 2015
    #128
  9. kiffsta

    kiffsta Senior Member

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    I would unplug the hole and route the hose onto there
     
    kiffsta, Aug 9, 2015
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  10. DougFella

    DougFella Well-Known Member Premium Member Contributing Member

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    Cheers mate I'll give that a try. If it is what's been causing the issue I'll kick myself.
     
    DougFella, Aug 9, 2015
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  11. Willrcr15

    Willrcr15 Well-Known Member

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    It's been a while, we had the same issue, that tube has to be connected to the box, it has something like pressurizing the carb bowls, puts a bit of pressure on top of the fuel in the bowls. Does your bike have ram tubes into the air box? If it does make sure its all nice & sealed up so you don't loose any of that ram pressure especially at speed when it's really working.
     
    Willrcr15, Aug 9, 2015
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  12. Phil

    Phil Senior Member Contributing Member

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    Just checked......Kiffsta is on the money :thumb_ups:
     
    Phil, Aug 9, 2015
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  13. DougFella

    DougFella Well-Known Member Premium Member Contributing Member

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    Nope it has ram tubes but they only cool the regulator. Interesting what you are saying about pressurizing the bowls, always thought it had to do something more than just sit there! Cheers for the helpful advise as usual all
     
    DougFella, Aug 9, 2015
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  14. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    :lolsign:

    Give that man a raise
     
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    GreyImport, Aug 9, 2015
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  15. DougFella

    DougFella Well-Known Member Premium Member Contributing Member

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    One of two things will happen with this bike. It will either be fixed by the weekend.... or I'm going to take the fuel line off and accidentally park it over the top of a campfire

    After my last update I couldn't get it to start the next day! So between now and then I've had the carbies off for another disassemble and adjust. Ive replaced the coils, cdi and rewired cdi electrical connection, regulator, plug leads and cleaned the plugs off. Modified the airbox base to get a better seal/fit round the carbs. Checked for vacuum leaks round the seats. Then i put it back together and over tightened a carb boot ring bending it into the way of the throttle connector bits under the carbs. Didn't realise till I'd reassembled everything then had to take it ALL OFF AGAIN!!!

    HOLY MOTHER HAVE MERCY ON ME.

    But it did start!!!! And it sounds really strong so tomorrow after work it'll be test ride judgement time again.

    Sent from my SM-G900I using Tapatalk
     
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    DougFella, Aug 13, 2015
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  16. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    hallelujah brother! :dance2:
     
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    GreyImport, Aug 13, 2015
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  17. kiffsta

    kiffsta Senior Member

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    good stuff Doug, almost there
     
    kiffsta, Aug 13, 2015
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  18. Phil

    Phil Senior Member Contributing Member

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    fingers crossed that tomorrow all goes well, will be party time at Doug's if it does :thumb_ups:
     
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    Phil, Aug 13, 2015
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  19. risky

    risky risky

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    AH MEN.
     
    risky, Aug 13, 2015
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  20. DougFella

    DougFella Well-Known Member Premium Member Contributing Member

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    Crying.jpg IT WORKS

    I took the bike down the local backstreets this arvo. It's like a completely different bike, no misfiring, no flat spots, no inconsistent performance. It is amazing. 27 months I've had the bike, worked on and off, hundreds of hours and in the end all it needed was everything important replaced.

    Now I have to wait a torturous weekend to get it registered next week before I can ride. The work will continue, I'm going to keep improving on what I have now!
     
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    DougFella, Aug 14, 2015
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