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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. kiffsta

    kiffsta Senior Member

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    When I have done this in the past , I have loosened the screw in the top of the tensionser housing and pushed the tensioner all the way up in there, then tighteneed the screw to secure the tensioner in place, then I attached the complete assembly to the crank case, then loosen off the screw and the tensioner then clicks in against the cam guide. Finally I tighten the screw up and we are sweet, your way works to, but mine means I dont have to use a screwdriver to hold the tensioner in place while I do up the 2 x 8mm bolts.
     
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    kiffsta, Jul 3, 2013
    #21
  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Like any tradie a mechanic will charge a fortune to even blink in your presence...
    I would guess all he will do is take out the tensioner and put it back..... and Im no expert but I would think the only way to test it is to run the motor and if the chain is rattling like stink then theres a problem.
    Obviously u have the motor out and cant do that.

    The best thing I would do is remove it again yourself and check again for any damage (as in the link u posted) then put it back and see if it goes the same as before....as in it "springs" back when u release the screwdriver from the shaft.
    Maybe even put a little engine oil on the bits before u put it together.

    Then cancel the mechanic and wait till u have the motor running again to see how the chain sounds. :D

    Heres some blurb on the Ninja CCT .....

    http://faq.ninja250.org/wiki/Cam_chain_tensioner_removal
     
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    GreyImport, Jul 3, 2013
    #22
  3. risky

    risky risky

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    if the screw pulled the thread out get a new high tensile or stainless screw at that sixze abnd 1 bigger and try the new same size first and if no bite try the next size. the hitensile will often cut a thread in alloy. alloy grows to steel so on final screw in use some neverseize.
     
    risky, Jul 3, 2013
    #23
  4. risky

    risky risky

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    good advice from grey and kiffsta.
     
    risky, Jul 3, 2013
    #24
  5. zxaar

    zxaar Member

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    I agree, great advise(thanks for that btw :) ) I did get the screw out in the end but the head of the screw is pretty stripped out yet the actual thread is still good so I'll be replacing the screw in the morning with a new one. Problem solved.
    When I'm down at the shop in the morning I will also be getting a new torque wrench to reassemble the top end. Once this is all done I can give the motor a good degrease then put it back in the bike to give her a run and see how she goes.
    The main reason the head came off in the first place was because I thought it may have been the cause of the engine getting hot when running which wasn't the case. I checked the thermostat just before which is working as it should be so once the bike is back together I'll be checking to see if the fan works which I have a feeling it won't as the sender in the radiator that switches it on once it reaches a certain temp is more than likely faulty so it would be a good idea for me to wire it to the ignition so it stays on all the time.
     
    zxaar, Jul 3, 2013
    #25
  6. kiffsta

    kiffsta Senior Member

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    could well be the sender
     
    kiffsta, Jul 3, 2013
    #26
  7. zxaar

    zxaar Member

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    That's very true. I have run into another problem now... When I was doing up the fitting near the thermostat where the hose connects(which I later found out didn't need to come off anyway) I had it upside down and I cracked the alloy piece. I am so angry at myself right now. Here's a pic of the part I mean.
     

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    zxaar, Jul 3, 2013
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  8. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Welcome to old bikes ...... :dance2:

    Just punch the wall and drink more beer

    :D
     
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    GreyImport, Jul 3, 2013
    #28
  9. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Just a suggestion.
    "I did get the screw out in the end but the head of the screw is pretty stripped out yet the actual thread is still good so . . . . "
    That problem is probably caused by your dire need for a JIS Cross Head screwdriver. Do not use phillips screwdrivers because there are no phillips screws on your Japanese motorcycle.
    cheers
    Blair
     
    maelstrom, Jul 3, 2013
    #29
  10. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    GreyImport, Jul 3, 2013
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  11. zxaar

    zxaar Member

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    Oh ok, that's good to know. Learn something new every day:thumb_ups: . I'll definitely look into getting a JIS cross head screwdriver. Thanks for the advise. Now about the piece that I cracked just above the thermostat where the hose connects, I took some more pictures to show Chris the piece that I am talking about because I rang him before and he was kind enough to sell me one of his spare one's. Thanks alot mate, much appreciated :) It is directly between the intake of the head and the thermostat housing. That's the best I can explain it as I have no idea what the piece is called..
     

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    zxaar, Jul 3, 2013
    #31
  12. risky

    risky risky

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    could be tig welded but that would cost more than a used one,with alloy always use neverseize on all studs, bolts and nuts. where something could vibrate off use nylock nuts. by the way jap metric has a pitch of 1.25 not euro metric which is1.50 pitch.
     
    risky, Jul 3, 2013
    #32
  13. Murdo

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

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    Hi zxaar, I have my own TIG and if you want to post it to me in Tamworth I will weld it up for you. You just pay the postage both ways. And don't panic, we have all been there when thing have seemed hopeless.
     
    Murdo, Jul 3, 2013
    #33
  14. zxaar

    zxaar Member

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    Thanks for the offer Murdo, that was nice of you mate but I'll be on the east side of Brissie tomorrow picking up some new tools so it will be easier for me to just drop around Chris's place while I'm in the area and buy one of his spare one's.
     
    zxaar, Jul 3, 2013
    #34
  15. kiffsta

    kiffsta Senior Member

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    PM sent
     
    kiffsta, Jul 3, 2013
    #35
  16. Phil

    Phil Senior Member Contributing Member

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    Hey Shaun
    You've had a few nerve racking days :help: , but most issues can be remedied with help and I'm pleased to see your getting plenty of that from forum members. I think your heading in the right direction and it won't be long before that bike is firing away nicely, keep up the good work mate :thumb_ups:
     
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    Phil, Jul 3, 2013
    #36
  17. zxaar

    zxaar Member

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    Thanks Phil, yeah I've had my moments and made a couple of mistakes here and there but at the end of the day if I don't make any then I won't learn from them. It will all be worth it when she is finished at which point my smile will go from ear to ear. I have already learnt alot in the last week or so but the more I learn, the more I realise I have yet to learn. The motor is going back together tomorrow afternoon after I pickup my new torque wrench and a few other goodies so I'll keep you's posted on how I go.
     
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    zxaar, Jul 3, 2013
    #37
  18. risky

    risky risky

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    best way to learn is from experience. age helps....ask grey.lol.
     
    risky, Jul 4, 2013
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  19. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    yup..... 60 in 10 days .... pity the body cant keep up with the knowledge.

    Just think Shaun ,when me and risky are pushing up daisies you will be on here giving the young ones the run down.

    risky ,is it this year or next u turn 85? :dance2:

    :D
     
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    GreyImport, Jul 4, 2013
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  20. zxaar

    zxaar Member

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    Wow, happy 60th for ten days time mate :drinks: - You know what they say though... "Age is a question of mind of matter, If you don't mind, it don't matter"

    Did a little bit of shopping today, got some new tools to make life a little easier and picked up the part that I broke from Chris today(Thanks heaps for that btw) so all is good now and the top-end of the motor can go back together this arvo/tonight. :thumb_ups:
     

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    zxaar, Jul 4, 2013
    #40
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