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Shaun's ZXR250 A model Build Thread

Discussion in 'Kawasaki 250cc In-line 4's' started by zxaar, Jul 2, 2013.

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  1. zxaar

    zxaar Member

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    Well the fun has started and I have begun to disassemble the bike for a closer inspection and a general tidy-up. So far I have removed the chain and dropped the motor out. The carbs have also been removed from the intake for inspection.
     

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    zxaar, Jul 2, 2013
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  2. zxaar

    zxaar Member

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    Ok, well I had a closer look at the carbs this morning and they seem to be very clean and none of the jets were gummed up with crap so I was pretty stoked about that. The float heights were all around 13mm so there was no need to adjust the float levels.
    The carb to airbox gaskets could do with a replacement as they've seen better days.
    I also noticed one of the springs in the slide/diaphragm was getting caught and only allowed the slide to open half way so I pulled it apart and refitted it and now all the slides open up 100% If I get a chance the head will be coming off today to see if the head gasket is cactus or not. Starting to make some progress now... YAY!! :)
     

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    zxaar, Jul 2, 2013
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  3. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    While u have everything apart pull the carb > manifold boots off and check their condition....
    carb boot cracks.jpg
     
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    GreyImport, Jul 2, 2013
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  4. zxaar

    zxaar Member

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    Good idea, I'll have a look when I get home. I can see how a cracked/split boot
    Could be a problem with a bike that is running lean. I also found a split vacuum
    Hose which will need to be replaced. TBH it is worth changing all the vacuum and fuel
    Hoses as they have all become hard after the last couple of decades being on the bike.
     
    zxaar, Jul 2, 2013
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  5. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Definately ..... vacuum and fuel hose etc is a cheap and easy thing to do .... apart from age and heat they are open more to the elements on a bike.
    I was desperately wanting to replace the cooling hoses with sexy silicon ones on the Fizzer but sadly half of them have different diameters on each end so are a special part..... why they arnt all the same fittings Mr Yamaha only knows :headbang:
     
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    GreyImport, Jul 2, 2013
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  6. zxaar

    zxaar Member

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    Ok, I got the head removed and had a look at the head gasket which was in perfect condition so there wasn't really any need for me to remove it in the first place. I just thought that it may have been faulty as the bike was getting hot after running for a while.
    I am having a little drama now though because when I undid the cam chain tensioner it sprung out and now I have no idea how it goes back together.
    Below is a pic of the disassembly of the top-end, the split vacuum hose and the cam chain tensioner on a red rag in it's disassembled form.
    Does anyone have any idea at all how the cam chain tensioner goes back together? I had a look at the manual but it is impossible to see the picture properly. Worst case scenario is I will have to take it down to the bike shop when I have the $$ to get them to install it. Thanks guys.
     

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  7. zxaar

    zxaar Member

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  8. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    If you are not in a hurry, then those carb to head gaskets, part number 92055-1458, will be part of my ZXR250 kits in the near future.
    cheers
    Blair
     
    maelstrom, Jul 2, 2013
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  9. zxaar

    zxaar Member

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    I just spent the last 4 hours trying to install the bloody camchain tensioner and had no luck. Is there someone in the Beaudesert area that could possibly help me? I am just about ready to give up :(
     
    zxaar, Jul 3, 2013
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  10. zxaar

    zxaar Member

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    I think the reason the camchain tensioner won't go back in is because the screw won't undo and the shaft isn't sliding all the way in. I tried to loosen the screw but I stripped it...
     
    zxaar, Jul 3, 2013
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  11. kiffsta

    kiffsta Senior Member

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    I have some spares shaun... feel free to pop over for a look
     
    kiffsta, Jul 3, 2013
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  12. zxaar

    zxaar Member

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    I just got off the phone with a mobile motorcycle mechanic and he is coming around tomorrow to try and fix it for me so hopefully all goes ok...
     
    zxaar, Jul 3, 2013
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  13. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Its a different setup than the Fizzer but same principle....the shaft has to be held back while u bolt the whole thing on then when u pull out the little screwdriver the shaft will spring out onto the chain inside.
    To me it looks like the screw is only there to cover the whole.

    If its stripped u may have to it drill out .......... is it just turning endlessly or is the philips head chewed up?
     
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  14. zxaar

    zxaar Member

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    Hi Chris, unfortunately I have no way of getting over there atm. The bloke coming out tomorrow may be able to get the screw out with a little bit of luck so fingers are crossed
     
    zxaar, Jul 3, 2013
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  15. zxaar

    zxaar Member

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    The philips head screw is pretty much stripped out unfortunately.
     
    zxaar, Jul 3, 2013
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  16. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Get some multigrips (or pliers) onto the head and as u turn slowly ,pull upwards as well ..... sometimes if its just turning endlessly it just needs a little pull to make it grip in the next thread.

    Or push something into the open end so it pushes on the base of the screw as u turn

    Be careful not to damage the unit though.
     
    GreyImport, Jul 3, 2013
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  17. zxaar

    zxaar Member

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    Ok, well by some miracle I managed to undo the screw, I then put the long spring into the inside of the metal rod and the bearing on the shaft with the bigger spring where it's meant to go, I then pushed it into the camchain tensioner casing, got a precision screwdriver to hold it in where it needed to be and it installed correctly because when I pulled the screwdriver out it sprung into place then I did the screw up. Hopefully I got it right but I will double check when the mechanic comes out tomorrow. Wow that was hard to explain the process but hopefully you got an idea of how it went together..
     
    zxaar, Jul 3, 2013
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  18. zxaar

    zxaar Member

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    The first pic explains how it goes together and the second pic shows how it needed to be held in place in-order to install. Without the screw being able to undo there is no way to get a screwdriver in there to hold the shaft in place. Just make sure that the two 8mm bolts holding it down are done up before pulling the screwdriver out. Hopefully this may help some people who are struggling with the same issue. So happy that it's back in place now :)
     

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    zxaar, Jul 3, 2013
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  19. risky

    risky risky

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    be careful with mobile mechanics as here in newcastle one lot want over$100 to turn up.something like loob mobeel.
     
    risky, Jul 3, 2013
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  20. zxaar

    zxaar Member

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    Wow, that's a bit steep. I might just take the motor to his workshop, saves the callout fee and he would have all the tools required in-house. Really I won't need him to install anything now that the tensioner in done, but it would be good to get his opinion on whether or not it is installed correctly which I'm pretty sure it is.
     
    zxaar, Jul 3, 2013
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