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Project Project Work Bike-ZXR250C

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

  1. PilbaraGuy

    PilbaraGuy Member Premium Member Contributing Member

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    Cheers Andych will have a look about.


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  2. PilbaraGuy

    PilbaraGuy Member Premium Member Contributing Member

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    Finally got around to working on the bike again. Got most of my parts in order before all the **** started. Took ages to get a few parts like valve stem seals as things were just starting to shutdown & shipping took ages.
    Painted my frame in clearcoat today & was real surprised with the results. When I sprayed it on it was very orange peel texture. But after a while it came out not too bad I thought. I used KBS Diamond Finish. Still waiting on a respirator so I could paint this stuff but got sick of waiting & had to borrow one.
    Pretty happy with the results...


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  3. PilbaraGuy

    PilbaraGuy Member Premium Member Contributing Member

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    Been working on & off on my project. Resealed forks, frame assembled & wheels painted. I was trying to get factory colours to match but ended up going with these off the shelf colours as they were easy to get & didn't cost a fortune/waiting time in freight.
    I think they will look the part ...
    Once tyres arrive & frame is rolling will start stripping/rebuilding engine.
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  4. PilbaraGuy

    PilbaraGuy Member Premium Member Contributing Member

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    Fitted tyres & put frame together loosely so I would not loose parts then started to strip engine down last night to see condition.

    WELL...they do say you get what you pay for!

    I found out why my engine would not start after about 20 minutes of run time initially before I pulled bike down. The #3 piston has dropped part of the oil ring into the cylinder & scored the bore. Looks like all the bores have been exposed to the weather as they have slight pitting in them. The score on #3 looks to be too deep for repairs so I may be up for new cylinders/liners/pistons etc.
    Explains why she was blowing a bit of smoke but when running seemed to be OK, no misfires, noises.
    I was told by previous owner that it had been rebuilt at some point but when I lifted cylinder head/barrels off the gaskets had sealant/Hylomar all over them possibly blocking oil ports so not a great job.
    Can anyone tell me if the new liners that you can buy have a finished/honed bore & just press into place with o'ring or are they sold as an unfinished undersize & then get bored/hones once installed? I have read the service manual & it does not shed any light on this.
    Any Ideas on parts/ reputable machine shops to carry out this kind of work in Australia appreciated.
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    Hopefully I can get hold of some parts & get it running before the tyres go hard.
    I think for my next project I will start with the motor then work back to the frame just in case it is too far gone...
     
  5. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    OUCH

    I can tell you that FZR cylinder sleeves are dropped into place in the barrels, therefore replaceable, CBR250 barrels are cast in place, therefore not replaceable

    ZXR250 barrels may or may not be replaceable, if they are there may be suitable sleeves from LA Sleeve if you go that route, they are supplied undersize to be bored ad honed to the final diameter

    Otherwise there may be oversize piston and ring sets available on Aliexpress which a few have used with no issues on other bikes

    EDIT - nothing visible on Aliexpress

    Balius oversized pistons and rings listed here ~$120 per cylinder, however as I have learned just because something is listed on a website in a parts breakdown and even listed as available, Yamaha in my case, doesn't mean it's actually available

    http://www.robmc.com.au/partFinder/fiche/kawasaki-motors/1999/zr250-balius/b-5-cylinder-piston-s

    Interestingly, from the parts breakdown, it looks like the sleeves are pressed in, so you could make on from two if you've able to source another set of sleeves and pistons or just do a straight swap
     
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    Last edited: Oct 27, 2020 at 2:51 PM
  6. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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  7. PilbaraGuy

    PilbaraGuy Member Premium Member Contributing Member

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    Thanks for the info ruckusman & Linkin. Looks like I will be trying to get hold of some new liners & get fitted/machined.
    Things are getting expensive pretty quick for the little pocket rocket.
    Can't turn back now... I got emotionally attached the day I got it running & heard the exhaust note:Drool:
     
  8. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    You may be able to just get another set of barrels in good condition and new OEM rings - much more cost effective, or bore the lot oversize and go OEM pistons and rings if they're actually available
     
  9. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    What Ruckusman said. If you do go down the replacement sleeve path, just put the block in an oven at about 140 C and the sleeves will fall out. If they are stiff then take up by 20 degrees at a time. If you can't find used parts locally try Jauce.com
     
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