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Project The ZXR250a boat anchor

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

  1. tarmacsurfer

    tarmacsurfer Well-Known Member

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    Back to it...
    I cut the original exhaust hanger and polished. Downpipes shot-blasted and VHT painted.

    smDSC_1290.jpg smDSC_1288.jpg
     
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    Last edited by a moderator: Aug 17, 2016
  2. tarmacsurfer

    tarmacsurfer Well-Known Member

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    Ran it up and 2 immediate problems:
    1. Oil dribbling from spark plug drain 4 - guess the rocker gasket is leaking - Ar$e - hopefully I can get to this without dropping engine.
    2. Engine only runs on choke, stalls with throttle. I guess an air leak but not sure where yet. I have the vacuum pipe plugged and thought carb rubbers were ok so need to investigate. Also pretty definite that pilot jets are clear as I used a sonic cleaner.
     
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  3. tarmacsurfer

    tarmacsurfer Well-Known Member

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    Chain and hugger fitted

    _20161203_185810.JPG
     
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  4. tarmacsurfer

    tarmacsurfer Well-Known Member

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    and after a fair bit of hassle I have a very special present from Japan. Best not to think about the cost! :-o


    _20161203_190121.JPG
     
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  5. tarmacsurfer

    tarmacsurfer Well-Known Member

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    My Bike:
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    New cam cover and spark plug hole gaskets fitted.
    New intake rubbers on order after found a split in one so that should sort the running.
    Then attention will turn to the bodywork.
     
  6. sharky

    sharky Well-Known Member Premium Member Contributing Member

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    Just read that whole thread from start to finish, nice work, looking forward to seeing that one finished
     
  7. tarmacsurfer

    tarmacsurfer Well-Known Member

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    My Bike:
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    Small update:
    Engine is running now - stripped the carbs again and found all 4 slow (idle) jets blocked. I did manage to clear them but also bought & fitted new jets as they're only ~3 quid each. Sounds lovely with the Mivv !

    Bought LED indicators all'round. They look good but were a bit of an arse as you need to swap out the flasher relay for one with balance resistors AND do a wiring mod using diodes for them to work properly. The 2nd bit I wasn't aware of but is courtesy of Kawasaki saving a few quid by not having a ground on the dash indicator light.

    For those interested in doing the same, the wiring diagram (stolen from Triumph forum but the same :) ) is attached.
     

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  8. tarmacsurfer

    tarmacsurfer Well-Known Member

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    Flush led indicators mounted and tested - perhaps a bit 'marmite' but once the fairing is sprayed then I think it'll give a more modern look.

    Made a bracket to mount a HRC radiator overflow bottle. Seems to tuck quick nicely behind the side fairing.

    smDSC_1619.jpg smDSC_1621.jpg
     
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  9. Cbuzz

    Cbuzz Active Member Dirty Wheel Club

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    Wow man bike looks better than a new one! Great work.
     
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  10. tarmacsurfer

    tarmacsurfer Well-Known Member

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    My Bike:
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    Put some fuel in the tank and it was leaking around some bubbling paintwork on the lower edge. A bit of scraping/ sanding and it looks like I need some welding doing
    The other option would be to get another tank but there's not many around in the UK and I guess they could be equally as bad.
     

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  11. Murdo

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

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  12. tarmacsurfer

    tarmacsurfer Well-Known Member

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    Agree, does need sealing but probably better to have it professionally blasted to find any other holes first. Also some of them holes look a little big for sealer.
     
  13. tarmacsurfer

    tarmacsurfer Well-Known Member

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    Not made a decision on the tank so decided to strip the forks and have them powder coated matt black.
     

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  14. tarmacsurfer

    tarmacsurfer Well-Known Member

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    I decided to have the tank professionally welded in the end. Then I used POR-15 to seal it. Good stuff, it's a 3 stage process so quite time consuming but easy to use.

    The bodywork has gone off to be sprayed. I decided for a more contemporary paint job, rather than standard hopefully it'll work and look OK! I'll post some pics when it's on the bike
     
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  15. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Good work, look forward to seeing the pics.
     
  16. tarmacsurfer

    tarmacsurfer Well-Known Member

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    Ordered tyres .The only rear 18" 140 in UK widely available seemed to be a BT50. So went for this and a BT016 Pro front.
    The bike has a 120 front squeezed on by last owner. Doesn't seem the best idea so I've ordered a 110.
     
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  17. Mike Fulcher

    Mike Fulcher Active Member Premium Member Contributing Member

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    Awesome rebuild, I hope you were joking about the extra 30 ponies by using the red HT leads.
     
  18. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Dunlop Alpha's are the best tyre IMHO
     
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  19. Qimbo

    Qimbo Active Member

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    Alphas are insane


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  20. tarmacsurfer

    tarmacsurfer Well-Known Member

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    I've not seen them in 140 18" in UK.
     

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