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

Project Sharky's ZXR shed

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

  1. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

    Messages:
    8,365
    Likes Received:
    4,921
    Trophy Points:
    1,168
    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
    My clutch basket was a lot worse on the FZR ... just put them in the vice and file them flat ... take off only what u need to


    Basket 1.jpg basket 2.jpg

    basket 3.jpg
     
    • Like Like x 3
  2. ShaneP

    ShaneP Well-Known Member Premium Member Contributing Member

    Messages:
    1,680
    Likes Received:
    676
    Trophy Points:
    623
    Joined:
    May 12, 2014
    Gender:
    Male
    Location:
    Yeppoon
    My Bike:
    Yamaha FZR250 speed bike, Yamaha YZ/WR250F, Kawasaki ZX2R, Honda VTR250, DR350 (x 3.5), a couple of prototypes and whatever else.
    Bummer about the tools! I use a socket on a bench for the valves, but getting the collets back in is a royal pain. That's great work on the bike, too, looks great! If you want some more zxr250s to tidy up, I've got a few...
     
    • Like Like x 1
  3. Andych

    Andych Well-Known Member Premium Member

    Messages:
    2,368
    Likes Received:
    1,404
    Trophy Points:
    798
    Joined:
    Oct 6, 2016
    Gender:
    Male
    Location:
    Sydney
    My Bike:
    1987 Yamaha SRX250, Honda 1975 CB400F, Honda 1974 CB250 G5 ?
    Back a very long tome ago I was rebuilding the engine in my Fiat 124 Sports coupe (1968 model with DOHC) and needed to pull the valves. I didn’t have a valve spring compressor and was using a small die stock and had the valve well compressed when it slipped and a spring retainer flew up and hit me in the eye. Permanently damaged the eye and now the scaring means at some stage cataract surgery.
    Tale of the story, don’t be a cheap-arse and buy a compressor set. Even the cheap Chinese ones are far safer than trying to do it without the proper tools.
    It just isn’t worth the risk.


    Sent from my iPhone using Tapatalk Pro
     
    • Bummer Bummer x 2
    • Agree Agree x 1
  4. Murdo

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

    Messages:
    5,030
    Likes Received:
    3,957
    Trophy Points:
    1,148
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, XL250, CBR250, ZZR250 plus a few others.
    Lot of life left in that clutch basket yet. Nice work on the engine. Bugger about your tools.
     
  5. ShaneP

    ShaneP Well-Known Member Premium Member Contributing Member

    Messages:
    1,680
    Likes Received:
    676
    Trophy Points:
    623
    Joined:
    May 12, 2014
    Gender:
    Male
    Location:
    Yeppoon
    My Bike:
    Yamaha FZR250 speed bike, Yamaha YZ/WR250F, Kawasaki ZX2R, Honda VTR250, DR350 (x 3.5), a couple of prototypes and whatever else.
    Wow, that's no good, but luck not to have the eye, or both! If you puncture an eyeball you can get an immune reaction that takes out the other, too. I'd be worried that my spring compressor is just about as dangerous, anyway. And nearly all my tools are not the proper tool... When I go the my mechanic friend's workshop I get an education on real tools and how the tasks are meant to be done, but I also get a bit of an idea of the cost of having real tools, too!
     
    • Like Like x 2
  6. sharky

    sharky Well-Known Member Premium Member

    Messages:
    481
    Likes Received:
    324
    Trophy Points:
    273
    Joined:
    Aug 5, 2016
    Gender:
    Male
    Occupation:
    daredevil
    Location:
    Tweed heads
    My Bike:
    kawasaki zxr 250c
    I should have mentioned I have already done the file back trick once already, but I used a steel ruler & sandpaper.
     
  7. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

    Messages:
    3,729
    Likes Received:
    2,178
    Trophy Points:
    943
    Joined:
    Mar 18, 2014
    Location:
    Sydney NSW
    My Bike:
    '99 YZF-R6, '99 GSF250VY
    @sharky I have a good clutch basket from my C model if you want it
     
  8. sharky

    sharky Well-Known Member Premium Member

    Messages:
    481
    Likes Received:
    324
    Trophy Points:
    273
    Joined:
    Aug 5, 2016
    Gender:
    Male
    Occupation:
    daredevil
    Location:
    Tweed heads
    My Bike:
    kawasaki zxr 250c
    My motor is an "A" model, cant remember if the clutches are interchangeable?
     
  9. sharky

    sharky Well-Known Member Premium Member

    Messages:
    481
    Likes Received:
    324
    Trophy Points:
    273
    Joined:
    Aug 5, 2016
    Gender:
    Male
    Occupation:
    daredevil
    Location:
    Tweed heads
    My Bike:
    kawasaki zxr 250c
    Yes I think I will replace the pads, this is from months of council roadworks near a mates house, where they divert you onto a dirt road & over 3 weirs of salty fork deep water. 20190214_114255.jpg
     
  10. sharky

    sharky Well-Known Member Premium Member

    Messages:
    481
    Likes Received:
    324
    Trophy Points:
    273
    Joined:
    Aug 5, 2016
    Gender:
    Male
    Occupation:
    daredevil
    Location:
    Tweed heads
    My Bike:
    kawasaki zxr 250c
    Been waiting a few weeks for parts to arrive. I got a new cam chain tensioner for piece of mind & some new pads. A mate also got some pads & wavy rotors & bought me a set of rotors also for replacing a conrod & some painting I did last year. 20190310_105232.jpg
    Head gasket worked a treat no more bubbles, tensioner not yet installed & still need to sync the carbs etc.
     
    • Like Like x 1
    • Winner Winner x 1
  11. sharky

    sharky Well-Known Member Premium Member

    Messages:
    481
    Likes Received:
    324
    Trophy Points:
    273
    Joined:
    Aug 5, 2016
    Gender:
    Male
    Occupation:
    daredevil
    Location:
    Tweed heads
    My Bike:
    kawasaki zxr 250c
    Forgot to mention the seal kit worked a treat aswell, no flat spot around 2.5- 3000rpm now, could not get it to sit on 3000rpm.
     
  12. sharky

    sharky Well-Known Member Premium Member

    Messages:
    481
    Likes Received:
    324
    Trophy Points:
    273
    Joined:
    Aug 5, 2016
    Gender:
    Male
    Occupation:
    daredevil
    Location:
    Tweed heads
    My Bike:
    kawasaki zxr 250c
    Already started the next project, got this bike as a non runner last year in January the same time I got the last bike off Kiff. The bike done the rounds with a few different owners before a mate bought it & had a go himself, the bike has good compression but no spark. 20180119_110843.jpg 20180119_110937.jpg
     
    • Like Like x 3
  13. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

    Messages:
    3,298
    Likes Received:
    2,305
    Trophy Points:
    923
    Joined:
    Dec 23, 2012
    Gender:
    Male
    Location:
    Thailand
    Home Page:
    My Bike:
    Yamaha FZR400 3TJ1, Honda MC22
    Be a walk in the park for you Sharky.
     
    • Agree Agree x 1
  14. ShaneP

    ShaneP Well-Known Member Premium Member Contributing Member

    Messages:
    1,680
    Likes Received:
    676
    Trophy Points:
    623
    Joined:
    May 12, 2014
    Gender:
    Male
    Location:
    Yeppoon
    My Bike:
    Yamaha FZR250 speed bike, Yamaha YZ/WR250F, Kawasaki ZX2R, Honda VTR250, DR350 (x 3.5), a couple of prototypes and whatever else.
    I have an engine that was only sparking one coil. It seems that someone changed the pickup coil and the resistance is lower than spec. There were other issues with that engine so I didn't bother resolving it, but just a random symptom I thought I'd share. :-D
     
    • Informative Informative x 1
  15. sharky

    sharky Well-Known Member Premium Member

    Messages:
    481
    Likes Received:
    324
    Trophy Points:
    273
    Joined:
    Aug 5, 2016
    Gender:
    Male
    Occupation:
    daredevil
    Location:
    Tweed heads
    My Bike:
    kawasaki zxr 250c
    Had a look over the new project & noticed the things people have tried to get it running, new plugs & filter, tci(with price still attached) pickup coil lightly sanded back,bits of loom unwrapped, fusebox dangling,switch blocks still unscrewed etc. I started by taking everything off the bike & unwrapping the loom. 20190226_141804.jpg 20190226_141819.jpg
    Everything tested well, fusebox,tci & coils had power, stator & pickup coil were within spec, in fact everything worked except the spark across all four. I finally got a spare loom to check wiring configurations for each plug & noticed the ignition wiring differed from the loom connector. The ignition on the right was the one on the bike, but the loom connector matched the ignition wiring on the left. 20190225_142942.jpg
    20190225_143010.jpg
    Swapped the inner piece over & now sparking happily. 20190225_144532.jpg
    I thought all zxr ignitions were compatible. The electrical diagram in the manual is for later model zxrs & maybe Balius's, the earlier C models only have 7 wires in the 10 pin fusebox plug. I have another zxr here with a 240klm speedo & it has the wiring as per manual & 10 wires in the fusebox, & a completely different fusebox aswell. 20190315_173946.jpg
    20190315_174008.jpg @Linkin i know you rewired your tci,do you recall if your Malaysian spec zxr had that fusebox & all 10 wires in that plug?

    Also wired a new r+r plug that actually stays together. 20190313_111630.jpg
    20190313_122002.jpg
     
    • Like Like x 1
    • Nice Work Nice Work x 1
  16. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

    Messages:
    3,729
    Likes Received:
    2,178
    Trophy Points:
    943
    Joined:
    Mar 18, 2014
    Location:
    Sydney NSW
    My Bike:
    '99 YZF-R6, '99 GSF250VY
    I didn't rewire my TCI... I replaced it with a Lixianda unit from aliexpress, it was plug and play.

    I did replace the standard coils with Ninja 300 stick coils, wired as two pairs, each coil in series with another.

    Interesting that the ignitions are different... wonder what bike the non-working one is really from.
     
    • Like Like x 1
  17. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

    Messages:
    3,497
    Likes Received:
    1,989
    Trophy Points:
    898
    Joined:
    Jun 18, 2016
    Gender:
    Male
    Occupation:
    Panel Beater, Spray Painter, Custom Fabricator
    Location:
    Adelaide, South Australia
    My Bike:
    Yamaha's, 1990 FZR250R 3LN3 , 1986 XT250TS 57R , 1984 IT200L 43G
    • Like Like x 1
    • Agree Agree x 1
    • Informative Informative x 1
  18. sharky

    sharky Well-Known Member Premium Member

    Messages:
    481
    Likes Received:
    324
    Trophy Points:
    273
    Joined:
    Aug 5, 2016
    Gender:
    Male
    Occupation:
    daredevil
    Location:
    Tweed heads
    My Bike:
    kawasaki zxr 250c
    20190316_175105.jpg
    This is the standard fusebox on most A & C models with 7 wires in the 10 pin plug (on left). Mmm interesting, 94-2008 that kinda confirms my thoughts on the manual wiring diagram being for the later model zxrs.
     
  19. sharky

    sharky Well-Known Member Premium Member

    Messages:
    481
    Likes Received:
    324
    Trophy Points:
    273
    Joined:
    Aug 5, 2016
    Gender:
    Male
    Occupation:
    daredevil
    Location:
    Tweed heads
    My Bike:
    kawasaki zxr 250c
    Dropped the motor out & removed the whole rear end, everything is quite filthy. 20190228_150226.jpg
    20190306_152036.jpg
    20190306_152100.jpg

    Used my last seal kit on the carbs & serviced the front & rear brakes. 20190220_173727.jpg
    20190317_132044.jpg
    20190318_133120.jpg
    20190319_164558.jpg
     
    • Nice Work Nice Work x 3
    • Like Like x 2
    • Winner Winner x 1
  20. sharky

    sharky Well-Known Member Premium Member

    Messages:
    481
    Likes Received:
    324
    Trophy Points:
    273
    Joined:
    Aug 5, 2016
    Gender:
    Male
    Occupation:
    daredevil
    Location:
    Tweed heads
    My Bike:
    kawasaki zxr 250c
    Tidied up the front,rear & mainframes etc, the wheels could do with fresh paint though. 20190328_114743.jpg
    20190328_114815.jpg
    20190328_124807.jpg
    Had to get the compressor onto the motor for a clean to make it easier to handle. The front of the motor above the headers was 10mm deep in crud, usually it's from the cover gasket (which will be replaced), but if the leak is over near the oil return hose, it's usually missing the o'ring off the cam cover, & bingo. 20190328_123316.jpg Also noticed a lug missing from the head for the cam cover, replaced that also.
    The cam cover was way over torqued, set back to the correct 6Nm. 20190328_123223.jpg
    20190315_122626.jpg
    Serviced the clutch as it was a little sloppy, found the problem, the shift shaft mechanism has a spring which is held in place by a circlip that was missing, replaced the circlip & feels much better. 20190331_144507.jpg
    Got the dremel onto the motor & cleaned up nicely. 20190320_142742.jpg
    20190320_142756.jpg
     

    Attached Files:

    • Nice Work Nice Work x 4
    • Winner Winner x 1

Share This Page