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

Project The ZXR250a boat anchor

Discussion in 'Your 250cc Projects' started by tarmacsurfer, Jul 20, 2014.

  1. tarmacsurfer

    tarmacsurfer Well-Known Member

    Messages:
    139
    Likes Received:
    84
    Trophy Points:
    228
    Joined:
    Jun 27, 2014
    Gender:
    Male
    Location:
    UK
    My Bike:
    ZXR250a, KTM 1190, 750 slabby, BSA Sunbeam
    Eventually getting around to finding time to post a few pics of the current restoration.. :)
    Bit of history first, I'm based in the UK and been involved with bikes for over 20 years. Started racing them for 5 odd years, then track days and now (due to lack of time/ money) doing a few projects.

    Previously I did a first-model 1985 GSXR750 slabside to near concours. It looks great IMO but was a bit of a ball-ache as being an original build then most parts have to come from Suzuki or be carefully restored.
    The ZXR (as you know prob) is very rare in the UK but I got a cheap one for 360 quid and there's a small reason for that as you'll see in the pics. However, I don't mind as this is intended to have many aftermarket parts fitted and only mildy sympathetic to original.
     
  2. tarmacsurfer

    tarmacsurfer Well-Known Member

    Messages:
    139
    Likes Received:
    84
    Trophy Points:
    228
    Joined:
    Jun 27, 2014
    Gender:
    Male
    Location:
    UK
    My Bike:
    ZXR250a, KTM 1190, 750 slabby, BSA Sunbeam
    First the bike as I got it. It'd been stood for up to 5 years in a shed and then cast outside. It did 'run' before that and had new jets...

    P1020223sm.jpg P1020215sm.jpg
     
  3. tarmacsurfer

    tarmacsurfer Well-Known Member

    Messages:
    139
    Likes Received:
    84
    Trophy Points:
    228
    Joined:
    Jun 27, 2014
    Gender:
    Male
    Location:
    UK
    My Bike:
    ZXR250a, KTM 1190, 750 slabby, BSA Sunbeam
  4. tarmacsurfer

    tarmacsurfer Well-Known Member

    Messages:
    139
    Likes Received:
    84
    Trophy Points:
    228
    Joined:
    Jun 27, 2014
    Gender:
    Male
    Location:
    UK
    My Bike:
    ZXR250a, KTM 1190, 750 slabby, BSA Sunbeam
    The tank was beyond saving but managed to get another for 50 quid.
    The shock was also foobar so I've got a Hagon replacement on order.

    Dsc_0592sm.jpg P1020271sm.jpg
     
  5. tarmacsurfer

    tarmacsurfer Well-Known Member

    Messages:
    139
    Likes Received:
    84
    Trophy Points:
    228
    Joined:
    Jun 27, 2014
    Gender:
    Male
    Location:
    UK
    My Bike:
    ZXR250a, KTM 1190, 750 slabby, BSA Sunbeam
    Swingarm, subframe and other brackets are off to be powdercoated.


    P1020272sm.jpg P1020286sm.jpg
     
  6. tarmacsurfer

    tarmacsurfer Well-Known Member

    Messages:
    139
    Likes Received:
    84
    Trophy Points:
    228
    Joined:
    Jun 27, 2014
    Gender:
    Male
    Location:
    UK
    My Bike:
    ZXR250a, KTM 1190, 750 slabby, BSA Sunbeam
    Engine isn't so bad - plugs look a good colour and ports all clean from quick inspection.
    I'm hoping this won't require a full rebuild at this stage but I'll do it if required.

    P1020274sm.jpg
     
  7. tarmacsurfer

    tarmacsurfer Well-Known Member

    Messages:
    139
    Likes Received:
    84
    Trophy Points:
    228
    Joined:
    Jun 27, 2014
    Gender:
    Male
    Location:
    UK
    My Bike:
    ZXR250a, KTM 1190, 750 slabby, BSA Sunbeam
    Other new bits that have arrived so far are:
    Trick wavy rear disc (from China.. hey, I never use the rear brake anyway!)
    New front discs (from UK, all silver)
    DID chain/ sprocket set
    Front seat
    Bearings

    I'm waiting on a complete front end and hoping it's ok as it's from Ebay (bit of a risk). The forks on mine require hard chroming and it's cheaper to source 2nd hand forks than have the originals chromed :(

    P1020275sm.jpg
     
    • Like Like x 2
  8. zixxer

    zixxer Well-Known Member

    Messages:
    457
    Likes Received:
    171
    Trophy Points:
    248
    Joined:
    Jan 26, 2014
    Gender:
    Male
    Location:
    Sydney, Australia
    My Bike:
    zxr250
    honestly doesn't look too bad, how many miles on the engine?
     
  9. Th3_Huntsman

    Th3_Huntsman Senior Member Premium Member Contributing Member

    Messages:
    2,426
    Likes Received:
    1,170
    Trophy Points:
    823
    Joined:
    Jul 1, 2013
    Gender:
    Male
    Occupation:
    Dispatch Manager
    Location:
    Beenleigh
    My Bike:
    NONE
    Over the updates and progress mate!
     
  10. Moo

    Moo Plodge Racing!!!

    Messages:
    1,040
    Likes Received:
    565
    Trophy Points:
    523
    Joined:
    May 7, 2014
    Gender:
    Male
    Location:
    Perth WA
    My Bike:
    Ninja 250R
    ahhhh good old rusty parts, i dont miss the uk and irish weather at all.

    looks good mate, i look forward in watching.
     
  11. tarmacsurfer

    tarmacsurfer Well-Known Member

    Messages:
    139
    Likes Received:
    84
    Trophy Points:
    228
    Joined:
    Jun 27, 2014
    Gender:
    Male
    Location:
    UK
    My Bike:
    ZXR250a, KTM 1190, 750 slabby, BSA Sunbeam
    About 34000km.
    Bought a zinc plating kit so will post a few updates on the process.
     
    • Like Like x 1
  12. tarmacsurfer

    tarmacsurfer Well-Known Member

    Messages:
    139
    Likes Received:
    84
    Trophy Points:
    228
    Joined:
    Jun 27, 2014
    Gender:
    Male
    Location:
    UK
    My Bike:
    ZXR250a, KTM 1190, 750 slabby, BSA Sunbeam
    All parts back from the powder coaters now. Decided to have the yokes done black for a more modern feel.

    Assembly started but still waiting (7 weeks now!) for a new Hagon shock.

    s_DSC_0715.jpg
     
    • Like Like x 1
  13. tarmacsurfer

    tarmacsurfer Well-Known Member

    Messages:
    139
    Likes Received:
    84
    Trophy Points:
    228
    Joined:
    Jun 27, 2014
    Gender:
    Male
    Location:
    UK
    My Bike:
    ZXR250a, KTM 1190, 750 slabby, BSA Sunbeam
    Also had a go at electrolytic cleaning and zinc plating.

    Cleaning went ok but plating didn't..
    I've ordered a fish tank airator (sp?) to help distribute the electrolyte better and I also don't think the items were clean enough. Time for another try !
    sDSC_0642.jpg sDSC_0644.jpg sDSC_0711.jpg sDSC_0712.jpg


    Once the shock is back then the rolling chassis should be ready very quickly.
    Wheels/ discs/ sprocket are done.
    Forks are ready - lowers sprayed black.
    Bars ready.
     
    • Like Like x 3
  14. Murdo

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

    Messages:
    4,185
    Likes Received:
    3,464
    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, XL250, CJ250, CBR250, ZZR250 plus a few others.
    Re the zinc plating; yes, you need a small fish tank pump to move the solution around, a fish tank heater also helps.
    If you are not using an adjustable amperage meter then try to get enough amps so that your parts are just giving off a wisp of bubbles (looks like smoke) when in the solution.
    I clean my bits by bead blasting, wire brush, wash with thinners then into the cleaning solution. Be sure to wash the parts in clean distilled water before putting into zinc solution. I also use the distilled in a spray bottle to wash zincing solution off the parts back into the zincing bucket before a fresh water (tap water) wash then wash with soap solution to remove all traces of the chemicals.
    Hope this helps.
     
    • Like Like x 3
  15. tarmacsurfer

    tarmacsurfer Well-Known Member

    Messages:
    139
    Likes Received:
    84
    Trophy Points:
    228
    Joined:
    Jun 27, 2014
    Gender:
    Male
    Location:
    UK
    My Bike:
    ZXR250a, KTM 1190, 750 slabby, BSA Sunbeam
    Thanks Murdo. Hopefully the air pump will help.
    I'm using an old van battery and wire coil to control the current (came with kit). Instructions say to keep the voltage between 0.8 and 2v and I was sitting at 0.95v - perhaps too low you think ? There was only a small amount of bubbles on metal surface during plating.

    One more question - can I sand the parts down a little then re-plate or do I need to chemically remove the previous plating attempt?
     
  16. Murdo

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

    Messages:
    4,185
    Likes Received:
    3,464
    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, XL250, CJ250, CBR250, ZZR250 plus a few others.
    Sanding/wire brushing and replating will be fine, just make sure the bits are clean (when water from a spray bottle beads on them).
    Maybe try less bits in the solution to get your amperage up. Whispy smoke like trails from the metal bits is what your after.
    I don't think an air pump is what you need, just one to circulate the solution.
     
  17. tarmacsurfer

    tarmacsurfer Well-Known Member

    Messages:
    139
    Likes Received:
    84
    Trophy Points:
    228
    Joined:
    Jun 27, 2014
    Gender:
    Male
    Location:
    UK
    My Bike:
    ZXR250a, KTM 1190, 750 slabby, BSA Sunbeam
    She's coming on. Red HT's add another 30bhp ;)

    I did the headlight wiring mod this weekend to run standard H4's. There's room next to the high beam relay and the extra relay slots in quite nice.
    It also means you can use the power from the existing relay.

    DSC_0875.JPG DSC_0874.JPG
     
    • Like Like x 4
  18. tarmacsurfer

    tarmacsurfer Well-Known Member

    Messages:
    139
    Likes Received:
    84
    Trophy Points:
    228
    Joined:
    Jun 27, 2014
    Gender:
    Male
    Location:
    UK
    My Bike:
    ZXR250a, KTM 1190, 750 slabby, BSA Sunbeam
    My footrest hangers were cracked so I decided to run aftermarket rearsets. Problem is, there's a very limited/ expensive choice for the ZXR (e.g. Beet).
    Therefore I did a basic design for an adapter plate which fits the majority of 'universal' rearsets and has 3 mounting positions. I then got a local engineering shop to make them up.

    DSC_0881.JPG DSC_0878.JPG
     
    • Like Like x 7
  19. Murdo

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

    Messages:
    4,185
    Likes Received:
    3,464
    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, XL250, CJ250, CBR250, ZZR250 plus a few others.
    Sweet!
     
    • Like Like x 1
  20. Damus

    Damus She is a BEAST and riding it is comparable to sex Dirty Wheel Club

    Messages:
    1,055
    Likes Received:
    414
    Trophy Points:
    493
    Joined:
    Mar 22, 2015
    Gender:
    Male
    Occupation:
    I.T.
    Location:
    Sydney, NSW
    My Bike:
    Honda CBR250RR
    AHHHH this looks like its gonna turn out good. I want the project to be further though lol, I enjoy looking at photos.
     
    • Like Like x 1

Share This Page