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Project Project Work Bike-ZXR250C

Discussion in 'Your 250cc Projects' started by PilbaraGuy, Apr 12, 2020.

  1. PilbaraGuy

    PilbaraGuy Active Member Contributing Member

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    Just thought I would share my "bargain" ZXR250 rebuild.
    Seen it for sale on facebook for $400. Talked him down to $200 & it started from there.
    I always liked the ZXR750 when I was younger but were always too dear so when I seen this I thought it would be a good project to use for commute to work & a bit of fun.

    zxr31.jpg

    After reading the forums here which were really helpful I cleaned carbys, got a kit from LiteTek as all the seals were cactus & got her running just to prove that it would before I strip it down for tidy up. Also checked valve clearances as it would only run for 5-10mins & then would not restart. Found that most of the clearances were too tight so re shimmed & after about $100 worth of shims it runs reasonable but still hard to start after 1/2hr so unsure about that. Will strip engine top end & check it all out when I get a chance. Started stripping her down yesterday, cleaning & today started stripping paint off frame, wheels so here is where I'm at...
    zxr11.jpg zxr28.jpg IMG_4026.JPG IMG_3997.JPG IMG_4029.JPG IMG_4024.JPG
    Used Selleys Kwik Strip & pressure washer to strip paint & it worked really well. Got the idea off another bloke on facebook. Can't believe how easily it comes off. Just going to be a pain in the arse to clean up all the old paint when finished.
    Front wheel tells a story. Looks like she's been through a few paint jobs over the years.
    I think it a Malaysian "C" model as it has made in Malaysia all over the inside of the fairings.
     
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  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Dont forget the wheel bearings

    Gotta love the screen :commando: :lolsign:
     
  3. PilbaraGuy

    PilbaraGuy Active Member Contributing Member

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    Had a quick try to get bearings out yesterday. They all seized & hard up against spacer. Will give it another crack later when I have more patience.
    Fairing has seen better days.
    Sounds like a good nickname tho Greyimport.

    Commando...


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  4. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Did u try tapping the spacer tube slightly off centre at one end? .... then u can get in from the other end with the big screwdriver to knock one out

    Theres also a marking in the bearing side of the sprocket carrier ... if u bed the carrier bearing past that line then when u fit the metal dowl/spacer thingy on the other side , the carrier doesnt sit flush on the wheel .... if that makes sense .... that was my assumptions at the time anyway

    https://www.2fiftycc.com/index.php?...odel-stealth-edition.1949/page-12#post-125890
     
  5. PilbaraGuy

    PilbaraGuy Active Member Contributing Member

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    Cheers
    I tried moving spacer to side but didnt give me much if a shoulder to hit against. I didn’t try too hard as I was more worried about stripping the paint.
    Will give it another crack.
    Thanks for the tip!


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  6. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Nice project. Definitely looks like a Malaysian model. The tell tale is the speedo, it should end at 240km/h and not 180km/h.

    You can get new plastic hoses from the fairing to the tank from Japan, but they were about $50 each when I bought them.

    [​IMG]
     
  7. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    If you can't push the wheel bearings out from behind and you're definitely going to replace them, then you can drive a couple of screws into them from the outside and use that to help pull them out. Don't go too far when drilling as you don't want to do any collateral damage to the wheel hub. Large wood screws are my preferred weapon of choice.
     
  8. PilbaraGuy

    PilbaraGuy Active Member Contributing Member

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    Thanks Frankster. They definately cactus so I’ll give it a try.


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  9. PilbaraGuy

    PilbaraGuy Active Member Contributing Member

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    [​IMG]
    Anyone got any tips to strip 2 pack paint(i think it is). Rear wheel was factory paint & came off easily but the front wheel looks like it has been blasted & painted in 2 pack? 3 coats of stripper so far & hardly bites in. Any tips?


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  10. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Sandblasting is good at removing tough finishes, finding someone with a large enough tub to do it might be a problem.
     
  11. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Most sand blasting places wont touch 2 Pak or Powdercoat because they have to get so aggressive that it damages the underlying substrate.
    Maybe get yourself some better stripper... your local Automotive paint store will have better stuff than the selleys or even Diggers.
    If all else fails... heat gun or lots of sanding..
     
  12. Murdo

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

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    I take my wheels to the powdercoaters and they blast and recoat them for around $150 pair.
    Try a panelbeater supply shop for some real stripper.
     
  13. PilbaraGuy

    PilbaraGuy Active Member Contributing Member

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    I ‘ll see what i can get hold of up here...No auto paint shops.
    I did use that magic 3 Bond carby cleaner when i reco’d them. Does that remove paint?


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  14. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Scuff any shiny paint with some 36 grit sandpaper to make it easier for the stripper to bite into it, but try not to scuff the alloy.
    Give it a thick layer (2mm thick) of stripper then carefully wrap it in glad wrap so the stripper doesn't start to dry out before it's working, the fume's it hold's inside the glad wrap help it work too
    Should only take 20 minute's to 30 minute's to fry up

    Any Crash shop's around They might be able to get it in for you ?
    East Pilbara Smash Repairs, Newman WA
    Otherwise you may need to have it freighted to you from Pt Hedland ?
     
  15. PilbaraGuy

    PilbaraGuy Active Member Contributing Member

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    Cheers my67xr
    Had a read of TonyZXR rebuild thread last night. Gave me some inspiration.
    That bike is going to a whole new level. Work of art.

    Perservered with stripper & pressure washer today as I had a bit of time up my sleeve & nowhere to go.
    Laid it out all day in the sun & recoated with stripper when it looked dry.
    Pressure washed it & she worked.
    There was a section that was real stubborn on the outer rim & after I finished had a closer look & it seems that the rim has been repaired before. You can feel the uneavenness of repair job.
    Hope this doesn't mean I need a new rim. Will look into it more.
    wheel 2.jpg wheel 1.jpg
     
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  16. TonyZXR

    TonyZXR Well-Known Member

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    Thanks for the kind words, yeah it was a damn nightmare, went through so much paintstriper and brass wire brushes , comes off the smooth outer rim easy but the rough cast finish in the centre far out... really should finish that bike.

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  17. PilbaraGuy

    PilbaraGuy Active Member Contributing Member

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    Painted frame & a few other bits today. It was hard to put the first coat of primer on
    as the frame looks so good in plain alloy but would be way too much work to
    keep in good nick. I am thinking of spraying a clear coat on frame to protect it.

    IMG_4249.JPG

    Does anyone know how to remove the riveted bolts on the steering head lock easily as I want to polish
    the top triple clamp without the lock in place. Any ideas?
    zxr steering 4.jpg
     
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  18. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    They're Shear Bolt's, the head of the bolt sheer's off once it reaches a certain torque.
    A sharp centre punch and hammer does the trick pretty easily
    Punch a ding into the washer part then angle the centre punch so it will undo the bolt anticlockwise as you tap it
    May take a couple of goes in different spot's


    What sort of paint did you use on the frame?
    And did you use any etch primer on the bare alloy ?
     
    Last edited: May 1, 2020
  19. PilbaraGuy

    PilbaraGuy Active Member Contributing Member

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    Cheers my67xr. I will try to remove lock tomorrow.

    The paint I used is just a Dulux Duramax spray can paint. Metallic Silver with Dulux Etch Primer undercoat.
    I wasn't really sold on the colour as I think it is really bright like the old silverfrost paint
    but maybe if I coat with clear it may take the shine out I hope. I'll see how
    it goes. I wanted a darker/duller silver but not much choice up here.
    I am going to try to get KBS clearcoat. I've read it should protect well.
    See how it turns out...
     
  20. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    See if you can get your hands on Eastwood Diamond Clear... they also do it in a satin finish
    http://www.ppcco.com.au/eastwood364.html
    You should also be able to get it on eBay.... I havent used the Satin but I have used the Gloss and it really is a good product.
     
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