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Official Kit build thread. (Picture heavy)

Discussion in 'Your 250cc Projects' started by Tim_, Apr 19, 2014.

  1. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    Ok so it's about time I stopped half arsing about and did the rebuild of Kit (name thanks to huntsman:crazypilot:). So here it is
    Make: Kawasaki
    Model: zxr 250 A
    Year: 1991
    Cc: 249 inline 4
    Cleaned and swept my garage last night knowing full well what the next day was going to bring.
    image.jpg
    image.jpg
    Started to take her gear off and noticed there was built up dirt and mud wasps nest.
    image.jpg
    Turns out the sub frame had a bit of cancer. Needed to get it off the bike and so rust proof paint on it.
    image.jpg
    Looks like the oil and filter have never been changed.
    image.jpg
    Thanks to a mate( more like silent sponsor) who has been helping out huge amounts with this bike I got a spare frame. I preped and painted it let it sit in the sun and bake on.
    image.jpg
    Blury but finally realised why the 2 centre carbs were not getting fuel. The vacuum line was spilt :commando: :headbang:
     
    Last edited by a moderator: Jul 5, 2014
  2. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    image.jpg
    Needed some motivation once the heat of the day got to me.
    image.jpg
    Arse end gone and ready for back wheel removal.
    image.jpg
    The end of the day. Sub frame, new frame and small of parts preped and painted. Rear wheel off, gauges off , right hand switch block off and carbs off. My plan is to choc the engine where it is. And lift the frame off the engine. Then put the new frame on.

    Also the name Kit is because she will be completely black with red highlights.
     
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  3. Th3_Huntsman

    Th3_Huntsman Senior Member Premium Member Contributing Member

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    Great work so far mate, wish I was there. Good find on the vacuum hose, she's gonna look sweet all black!
     
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  4. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    Forgot to post yesterday. So this is what's happened. Clip ons and top of triple clamp are off. Rear wheel is off and rear brakes, rear sets are off. Lots of brackets were painted. And I got to see the red paint which will be her highlights.

    Thanks again to my silent sponsor for the rear shock which happens to be the exact colour I needed.
    image.jpg
    The old frame and rear shock.
    image.jpg
    This is the new (used) shock and the frame.

    Today: I was at work and talking to a mate who paints all his car parts him self. When I told him I only put 2 coats of paint on the frame he laughed. So the engine didn't get removed today like I had planned. And may need to wait until Anzac Day. I put 200ml of oil back in the engine so the sump wasn't dry.

    So while I was waiting for the frame to dry I decided to get my old metal polishing mops and wax out and clean up the DIC exhaust(silent sponsor again). 4 more coats of paint and a few hours of metal polishing and this is the result.
    Before: image.jpg
    After: image.jpg
    The frame came up 100% better them what I had it. Can't that my mate enough for making put more coats of paint on it.
    image.jpg
     
  5. Phil

    Phil Senior Member Premium Member Contributing Member

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    Hey Tim
    Love your work, the exhaust came up a treat! Some serious elbow grease was used in that endeavour I'm sure.
    The frame looks awesome, think your bike is going to look amazing.:thumb_ups:
     
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  6. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    Cheers phil, one if my first jobs was a metal finisher fir riviera boat builders. So I had to mirror finish stainless all day. It's a dirty job but the pay out is worth it. I was trading on here and everyone seemed to say the same thing. Don't rush it. Do it properly the first time. And that's what I'm going to do.well to the best of my abilities.
     
  7. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    looking good Tim, make sure thsoe headstem bearings get a good coating of grease before refitting them.

    Cheers

    Chris
     
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  8. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    Cheers chris. Will do mate. I did see that the old ones Grease was shagged. The bearings looked good. No rust and nothing loose. Hopefully today will be the engine swap.
     
    Last edited by a moderator: Apr 22, 2014
  9. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    Loving auto correct grease.
     
  10. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    fixed that for ya
     
  11. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    Cheers Chris.
     
  12. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    Question time:
    How many coats of paint should a put on the engine?

    Can I use heat proof paint on the the radiator hoses? And will it crack?

    Will 200ml of oil be ok in the engine until the weekend?

    How long can I leave the coolant out before it cause issues?
    Any help with these would be a great help to me and my bike. Thanks guys.
     
  13. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    I didn't get any where near as much done as I wanted to. But it had to be done.
    image.jpg
    Tooth brush, towel and this stuff.
    image.jpg
    Looking rough and dirty and got to work cleaning all the connections and the entire harness.

    I wasn't happy with how the harness looked after the clean so I decided to re-tape the harness. So I still stuck with the red and black theme.
    image.jpg
    Put the smaller wires in black tape and the main part of the harness red.
     
  14. Willrcr15

    Willrcr15 Well-Known Member Premium Member

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    Paint the engine with an etch primer first on the bare metals then what ever you like, enamel from a rattle can or an epoxy or 2 pack, pay respect to all the drying times & it'll be good.
    I'm not sure about the radiator hoses, Rubber?, I wouldn't try to paint rubber, just clean up with detergent / degreaser & apply tyre shine or armorall or the like.
    The engine will be ok with no oil as long as you don't start it, Looks pretty black & aweful, I would do a quick oil change now, run some new oil for a couple of heat cycles, ie ride her a couple of times, then dump the oil & filter & fill her up again with new good quality oil & a good filter, these little engines rev big time so the cleaner the better & she'll last a lot longer.
     
  15. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    Thanks for the tips mate. I already changed the oil filter but will do again when the engine is back in the bike.

    Only asked about the hoses because I want red ones. Lol. And it's hard enough to find stock ones. I got heat proof engine paint that's a self primer. Or is that stuff crap?
     
    Last edited by a moderator: Apr 22, 2014
  16. Willrcr15

    Willrcr15 Well-Known Member Premium Member

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    It's probably ok, just make sure you clean the surfaces with everything you can get your hands on. Engines get oily & greasy & it gets into the metal, I have a detergent based acid cleaner for alloys that seems to get in, I usually leave the alloy never before painted parts un painted, the alloy cleaner does a good enough job, I just paint the covers etc that were painted before, sand blasted, primed & 2 pak. Your radiator will cool better un painted as well, paint the tanks if necessary.
    Your radiator will be ok for a while left dry, I have a ZXR that sat for 11 yrs & the radiator is still usable but it does leak / weep at the base of the tanks, a bit of Devcon soon fixes it so you get the picture.
    Keep up the good work right till the end & you'll have something of value & to be proud of.
     
  17. Russky

    Russky Careful, man, there's a beverage here! Premium Member Contributing Member

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    Great work Tim. especially the painting - love that ****
     
  18. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    Cheers mate. The build was on hold during this week. But tomorrow is the day. A mate from work lent me his W/B torque wrench so I can do the engine bolts. Plus I'm stuck on one thing. Should I do the rocker cover red and the rest of the engine black or entire engine black?
     
  19. Mclaren

    Mclaren Well-Known Member Contributing Member

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    Wouldn't do whole engine black incase oil leak hard to trace mate
     
  20. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    I'm thinking Matt black so the shiny oil will still show. And probably only one layer of paint just to get metal protect from the weather.
     

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