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Project Sharky's ZXR shed

Discussion in 'Your 250cc Projects' started by sharky, Jun 13, 2017.

  1. sharky

    sharky Active Member Premium Member Contributing Member

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    My Bike:
    kawasaki zxr 250c
    Got hold of a motor months ago now which was feeling a little rough to turn over by hand, had poured about a cup of oil down each plug hole & it has sat ever since, had another look yesterday & was still the same so it was time to strip her down & have a look. 20170222_123021.jpg zoom in on lower ring on 2nd piston, the ring is warped & not compressing around the piston fully. 20170221_184845.jpg Cylinder block looks fine though. The cylinder block & head were full of rust, so much so that I immediately cleaned it out before getting a pic of how bad it was.

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    The water pump was really rusty, the impeller & shaft will need replacing & the thermostat seal crumbled off, the radiator is rubbish & the hose mounts are near gone.Spent the rest of the day cleaning the motor parts which look ok & making gaskets, all the while thinking about honing bores, & $200 oem or $50 Chinese rings. With a mate wanting me to do up another zxr for him, everything was inoxed up & bagged for a later date- the whole motor-

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  2. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club

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    Nice one. Since you've recently had one apart, how hard does the selector shaft look to change? My second bike here may have just a bad seal or a bent shaft.
     
  3. sharky

    sharky Active Member Premium Member Contributing Member

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    Not hard at all to change, I couldnt pry out the seal & thought the shaft maybe bent also so I took the lot out but it was only the seal in the end. Remove the clutch basket

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    thats the selector shaft im pointing at, the cog above is the oil pump shaft, remove the oil cog off the shaft & the selector shaft pulls straight out.

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  4. sharky

    sharky Active Member Premium Member Contributing Member

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    The shark boat I work on was hired for the filming of the Aquaman movie recently, so I been away staying onboard for a month, this was sitting in the backyard when I got home last week. 20170523_132303.jpg I asked my girlfriend where the bike was from she just shrugged & said "I thought you put it there, its been there for 3 weeks", I checked back through all my missed calls/texts etc & found that my Virago loving mate had bought it for $600 & wants it done up like mine but black or blue. So I gave him a ring to find out about the bike & what he wanted done, "nothing major for now" he said, "just polish the frame, swingarm, outside rims, rear sets, exhaust pipe,the bit where the key goes & anything aluminium", as his rattling off his list im feeling the carb slides welded together thinking here we go again. 20170523_132421.jpg 20170523_132436.jpg 20170523_132405.jpg 20170523_132357.jpg 20170523_132325.jpg
     
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  5. sharky

    sharky Active Member Premium Member Contributing Member

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    Finally got a few supplies to move forward, new Lite Tek seals + new float needles & seats for the carbs, & a new ultrasonic cleaner. 20170712_150057-1.jpg I was having that much fun,I had them cleaned & rebuilt before realising I had picked up the wrong set of carbs, I had accidently grabbed the "A" model carbs from another project, so I ended up doing both sets. 20170715_212549.jpg 20170715_231201.jpg Replaced the JIS screws & fuel bowl screws with stainless allen heads, even polished the brass & butterflies with cotton buds.  20170707_130856.jpg Onto another topic, CLEANING OXIDIZED/STAINED ENGINE CASES. After much scrubbing & getting nowhere over the years I have really hit the information highway looking for something that might work even half as good as @kiffsta wet blaster, an acid by the name of Hydrofluoric kept coming up, its in products like mag wheel cleaner etc & its pretty nasty stuff in concentrated form, also known as the flesh eating acid. Bought this for a try. 20170715_165628.jpg The first method I tried on a carb failed miserably, I followed directions & mixed 3 parts water to 1 part Alum-bright, then dropped in an old single split carb, the mix frothed & bubbled & after 30 seconds pulled it up & looked good,60 seconds looked better, then the phone rang & 3 minutes later I was lookin at a dark greyish/black carb, whoops no more soaking. The next method would be brushed on & it worked a charm. Now it was time to try it on a piece of the split motor, what better piece than the sump. The sump was as clean as I could get it before I began. 20170715_165732.jpg before & after of the side done 20170715_174516.jpg 20170715_165651.jpg before & after, cleaned piece then quickly polished. 20170715_214316.jpg Looks like a new sink, very happy with how it come up for a rushed through trial in fading light, heres the method I used-- straight Alum bright brushed on sparingly for a couple of minutes then rinsed off in water, do this twice maybe more if theres stubborn patches, then I put it in the ultrasonic cleaner with detergent & degreaser on a hot 60deg + temp,dry off & then toothbrush on some alumimium polish & wipe off with paper towell, quick hit with carb or brake cleaner & wipe off with paper towell.
     

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  6. sharky

    sharky Active Member Premium Member Contributing Member

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    kawasaki zxr 250c
    Had the first real good look over this bike today, now that the carbs are done & the tanks de-rusted I can try and start this thing for the first time in 5-6 years soon. 20170523_132303-1.jpg The story with the bike is--the bike had electrical problems that were supposedly fixed, but there were bits hanging off that they did not know where it should go & they also couldnt install the fairing,so the bike just sat there until they lost interest. After looking today it all sounds legit, theres a new RR plug 20170717_172851.jpg & the only hanging bit that needed to go somewhere was the sidestand switch. 517049413-1-1.jpg Connected up a battery to check the electrics & found everything "fixed" and working after putting a main fuse in where the fuse should be, replaced both brake light & 2 indicator bulbs, re-wired both front indicators with new bullet connectors & connected the rear brake light switch, a couple of the dash lights needed a wiggle also to work. Gave the bike a wash down then blew out every electrical connection with the airhose & cleaned with circuit cleaner. 20170717_141635.jpg Things noticed so far that need replacing other than plugs, fluids etc- coolant overflow bottle(done), battery box(done), return excellerator cable, chain, front sprocket (prob rear too),brake pads,side fairing plugs & various bolts & screws. Tried the Alum bright on the rear footpegs aswell, does nothing to the steel though. 20170717_155328.jpg 20170717_163902.jpg 20170717_143151.jpg 20170717_164505.jpg
     
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  7. sharky

    sharky Active Member Premium Member Contributing Member

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    So I started the bike up a week later, that was 2 months ago now :(- unfortunately the video link posted elsewhere other than here.I was that keen to fire it up I didn't even notice the carby boots were all loose until I took the carbs back off, & that inoxy oily smoke coming off the rusty headers was not needed, the nuts were all loose, the throttle wasnt working properly either both cables were broken & installed wrong in the switchblock, Motor-wise everything looks ok with some valve clearances getting a little tight. So I started the make-over from the rear of the bike then said stuff it & pulled the lot apart, there was a lot of polishing & parts to look over. Some random pics 20170813_172004.jpg 20170813_172224.jpg 20170904_174804.jpg 20170911_123203.jpg 20170904_173608.jpg 20170911_123222.jpg 20170919_111305.jpg
     
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  8. ShaneP

    ShaneP Well-Known Member Premium Member Contributing Member

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    You are giving me unreasonable expectations for my ZX2R. Maybe I'll drop it in your backyard, too...
     
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  9. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club

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    Real nice work sharky
     
  10. beano

    beano Well-Known Member Premium Member

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    lots and lots of hours and effort gone into that!! give yourself a pat on the back........or several!!
     
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  11. sharky

    sharky Active Member Premium Member Contributing Member

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    Spent the last few days re-assembling the bike, the motor went in first then I worked from the back of the bike forwards, was good to have all the bits like caliper pieces back together & forks sealed up etc with the added bonus of extra floor space as I went. 20170919_111016.jpg 20170921_154635.jpg 20170923_125105.jpg 20170923_125119.jpg 20170929_180334.jpg 20170929_180341.jpg 20171004_173732.jpg
     
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  12. sharky

    sharky Active Member Premium Member Contributing Member

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    Havnt really done a great deal lately, I found & fixed an annoying indicator globe that worked when it wanted to, i thought it was a bad switch at first, then thought it was the housing for the globe itself but ended up being a badly joined & un-insulated wire on the loom that had rusted. Spent a whole day fitting the fairings, no wonder the previous owners couldnt get them on, had to get out the spare tail light mount, front fairing stay & lower rad mount to match the bent pieces & fashion them into shape again, every mount hole was out. Also soldered a voltmeter straight to the ignition. Got most of the missing nuts/bolts matched but I still need OEM front mudguard bolts, 2 side fairing plugs & the lower fairing cowl to join the side fairings. I still have to polish the rear sets etc, sync the carbs & paint the fairing blue or black at the owners choosing(i would stay blue) & make him a seat cowl like mine,but the owner wont be back until new years eve, thats 2 months away,so im already in need of another zxr to pull apart :cool:, hows yours going @Linkin any interest down there, Sydneys not that far from Tweed Heads really:lolsign:. 20171001_155324.jpg 20171001_155339.jpg 20171007_130926.jpg 20171007_132436.jpg 20171012_165233.jpg
     
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