1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

Project Risky's FZR250 2KR

Discussion in 'Your 250cc Projects' started by Linkin, Feb 19, 2016.

  1. risky

    risky Megelli King Premium Member Contributing Member

    Messages:
    3,647
    Likes Received:
    993
    Trophy Points:
    798
    Joined:
    Nov 4, 2012
    Gender:
    Male
    Occupation:
    risky by name AND actions
    Location:
    newcastle,australia
    My Bike:
    honda ca77, megelli x2,fzr yamaha x 5 ,maxim,cb750.cb600 hornet,zxr250,marusho magnum electra.
    wait till i chrissen your seat.
     
    • Like Like x 1
  2. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club

    Messages:
    2,878
    Likes Received:
    1,733
    Trophy Points:
    843
    Joined:
    Mar 18, 2014
    Location:
    Sydney NSW
    My Bike:
    ZXR250C
    Some progress :)

    [​IMG]
     
    • Like Like x 2
  3. Murdo

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

    Messages:
    3,899
    Likes Received:
    3,291
    Trophy Points:
    923
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    Picked up the frame bits from Linkin yesterday and home to block up all the important holes. Took to blasters today for a clean up.
    2KR 001.JPG
    Don't remember how I got talked into painting this but must have involved alcohol.
     
    • Like Like x 3
  4. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

    Messages:
    6,739
    Likes Received:
    4,078
    Trophy Points:
    943
    Joined:
    Jun 14, 2012
    Gender:
    Male
    Occupation:
    Troublemaker
    Location:
    North by NW NSW Oztralia - Tamworth
    My Bike:
    *Kawasaki ZXR250C *Yamaha FZR250R 3LN1 *Suzuki GSX250 *Triumph Bonneville 750 T140V
    Should have dropped it to me ... I have the perfect solution for it

    scrap.jpg
     
    • Like Like x 4
  5. risky

    risky Megelli King Premium Member Contributing Member

    Messages:
    3,647
    Likes Received:
    993
    Trophy Points:
    798
    Joined:
    Nov 4, 2012
    Gender:
    Male
    Occupation:
    risky by name AND actions
    Location:
    newcastle,australia
    My Bike:
    honda ca77, megelli x2,fzr yamaha x 5 ,maxim,cb750.cb600 hornet,zxr250,marusho magnum electra.
    and i hear sex change operations can be done with a blow torch.lol.
     
    • Like Like x 2
  6. Murdo

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

    Messages:
    3,899
    Likes Received:
    3,291
    Trophy Points:
    923
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    With Linkin away learning how to be a real motorcycle mechanic, I have picked up the reins on this one. Frame has been blasted and painted in two pack silver and I am now working on the engine. Valve and seats have been cut and new seals on order, ports de-burred and waiting on supplies of sanding disc to finish polishing.
    The bores are all scratched and worn at the top of the piston stroke, and new O/S piston kits on way, along with new timing chain and gasket sets. These verticle scratchings are what happens to bores when incorrect or no air filters are used.
    Dominator for sale 018.JPG
    To get the last three bolts out so I could get the cases apart I needed to remove the rotor. An incorrect threaded bolt had been tried before and had stripped the thread. I ground the end of a tap flat so I could clean up the thread and get the rotor off (some heat from a gas bottle torch helped)
    Dominator for sale 019.JPG Dominator for sale 020.JPG
    At last they are out.
    Dominator for sale 022.JPG
    Cases split and bearings are reasonable, but will be replaced to do the job properly.
    Dominator for sale 023.JPG
    A lot more difficult than the CBR.
     
    • Nice Work Nice Work x 4
    • Like Like x 3
  7. beano

    beano Well-Known Member Premium Member

    Messages:
    126
    Likes Received:
    103
    Trophy Points:
    248
    Joined:
    Jan 20, 2005
    Gender:
    Male
    Occupation:
    engineering student
    Location:
    Ireland
    My Bike:
    fzr250r 3ln-1 and yzf-r1 5vy
    murdo, you're like a god on this forum, the stuff iv'e picked up and learned from your posts over the last year!! unbelievable stuff, love all the pics they're a great help.
     
    • Agree Agree x 1
  8. Murdo

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

    Messages:
    3,899
    Likes Received:
    3,291
    Trophy Points:
    923
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    Thanks Beano, I'll try to do more for you.
     
  9. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club

    Messages:
    2,878
    Likes Received:
    1,733
    Trophy Points:
    843
    Joined:
    Mar 18, 2014
    Location:
    Sydney NSW
    My Bike:
    ZXR250C
    The cases are a pain on these. Head and barrels off required to split them. Are the MC19/22 different in that regard?
     
  10. Murdo

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

    Messages:
    3,899
    Likes Received:
    3,291
    Trophy Points:
    923
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    I only have the 19's, but head off, bottom case off and undo rods and push out through bores. Less tricky bolts you have to find when splitting cases too (particulary when you've not done one before and cannot read Japanese in manual).
     
  11. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

    Messages:
    7,004
    Likes Received:
    5,149
    Trophy Points:
    943
    Joined:
    Aug 7, 2010
    Gender:
    Male
    Location:
    Brisbane
    Home Page:
    My Bike:
    GSXR250, CBR250RR, CBR900RR
    Do you want to send me those cases and I will clean them up , if you are going to this much trouble with the rebuild then I am happy to do my bit and make them shine
     
    • Like Like x 1
  12. risky

    risky Megelli King Premium Member Contributing Member

    Messages:
    3,647
    Likes Received:
    993
    Trophy Points:
    798
    Joined:
    Nov 4, 2012
    Gender:
    Male
    Occupation:
    risky by name AND actions
    Location:
    newcastle,australia
    My Bike:
    honda ca77, megelli x2,fzr yamaha x 5 ,maxim,cb750.cb600 hornet,zxr250,marusho magnum electra.
    thanks for the offer. murdo can decide.
     
  13. Murdo

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

    Messages:
    3,899
    Likes Received:
    3,291
    Trophy Points:
    923
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    Thanks Kiff, I don't think it will be necessary.
    Doing a bit more on the head today. This is why you DON'T put silastic (or other silicone type sealers) into water fittings (or intake manifolds either). These fittings need O rings for seals, and I can understand using the silicone as a tempory/get home measure, but more is not better.
    Riskys 2KR 001.JPG
    Imagine if this big lump of blue poo came loose and went into your radiator, how many cooling tubes would it block? Cooked engine anybody?
    Riskys 2KR 004.JPG
    This is what it should look like. A bit of rubber grease on the seals to help them slide in and all will be good.
    Riskys 2KR 005.JPG
     
    • Like Like x 1
    • Agree Agree x 1
  14. my67xr

    my67xr Well-Known Member Premium Member

    Messages:
    1,886
    Likes Received:
    1,243
    Trophy Points:
    698
    Joined:
    Jun 18, 2016
    Gender:
    Male
    Occupation:
    Panel Beater, Spray Painter, Custom Fabricator
    Location:
    Adelaide
    My Bike:
    Yamaha's, FZR250 3LN3 1990, XT250TS 57R 1986, IT200L 43G 1984
    Goes to show some people shouldn't be allowed near engine's, or anything mechanical
     
    • Agree Agree x 1
  15. Murdo

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

    Messages:
    3,899
    Likes Received:
    3,291
    Trophy Points:
    923
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    Some people should not be allowed to buy tools. :lolsign:
    But I guess if they didn't then they wouldn't stuff anything up and we wouldn't have any cheap bikes to restore. :D
     
    • Like Like x 2
  16. Phil

    Phil Well-Known Member Premium Member Contributing Member

    Messages:
    3,617
    Likes Received:
    1,542
    Trophy Points:
    923
    Joined:
    Aug 8, 2010
    Gender:
    Male
    Occupation:
    M C E
    Location:
    Sunshine Coast Qld
    Home Page:
    My Bike:
    Suzuki GT250X7 Kawasaki ZZR600
    If nothing else........it is colourful !!!
     
  17. Murdo

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

    Messages:
    3,899
    Likes Received:
    3,291
    Trophy Points:
    923
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    Who would have thought that silicone sealer would come in so many different colours?
    The Intakes had red and blue on them. Will need some proper gaskets when I put it back together.
     
  18. Murdo

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

    Messages:
    3,899
    Likes Received:
    3,291
    Trophy Points:
    923
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    Pistons (+0.50mm) have arrived and taken with barrels to be rebored. Cases and components cleaned, inspected, bearings replaced, new cam chain, new seals and gaskets and ready to be reassembled.
    When fitting bearings it is important to check on the clearances, but also on the 'crush' of the bearing shells in the rod end. If not enough crush on the shells they may start to 'chatter' and will wear rapidly, possibly spinning in the rod end. To do this tighten the bolts to the correct torque, then release one side and measure how much the rod end has 'sprung' apart. These all came to .005", which is very good (.002" being the limit).
    zz 001.JPG
    All clean and ready to assemble.
    zz 002.JPG
    This is not OCD. I like to make sure I have all the bolts ready to go before I start so I don't get caught with drying sealer looking for the right bolt.
    zz 003.JPG
    All together and waiting for the barrels to come back.
    zz 004.JPG
     
    • Like Like x 4
    • Nice Work Nice Work x 3
  19. Murdo

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

    Messages:
    3,899
    Likes Received:
    3,291
    Trophy Points:
    923
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    Today I finished with the ports and after a through clean put the head together and set all the shims. Wrapped in clean rag waiting for barrels.
    zzz 006.JPG
     
    • Like Like x 4
  20. Murdo

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

    Messages:
    3,899
    Likes Received:
    3,291
    Trophy Points:
    923
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    Barrels back and looking good.
    Note the white rag with oil on it. My uncle taught me many years ago after a rebore/hone to wash with Kerosene, then hot soapy water a couple of times then wipe a white rag with oil soaked onto it up and down the bores and if any dirty marks appeared on the rag then there was still honing grit on the surfaces and it had to be washed again. Then wipe with another clean white rag to be sure, as nothing will wear a bore faster than leaving honing grit for the rings to grind with.
    zzr 6 008.JPG
    Pistons fitted and oiled.
    zzr 6 009.JPG
    Barrels on ready for head gasket. Have to wait as one of the dowels are missing and will be a while before I can get it.
    zzr 6 010.JPG
    So, who can tell me which one is the genuine gasket and which is the Chinese copy? They are both the same thickness and have same surface coating on them, and all holes line up excatly.
    zzr 6 011.JPG
     
    • Like Like x 1
    • Nice Work Nice Work x 1

Share This Page