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Project Tony's ZXR250

Discussion in 'Your 250cc Projects' started by TonyZXR, Apr 28, 2018.

  1. TonyZXR

    TonyZXR Active Member Premium Member

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    Retrimmed the pillion seat today . Came out great! Just have to get the trimmer at dad's work to retrim the strap . No way my sewing machine has enough power for that

    5c48a1b55da4aecba45086fd3323e81c.jpg

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  2. Andych

    Andych Well-Known Member Premium Member

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    Looks Factory
     
  3. risky

    risky risky

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  4. TonyZXR

    TonyZXR Active Member Premium Member

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    Let's see how this goes...
    27a3069cbca59072cd16c833fe1a4d39.jpg

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  5. TonyZXR

    TonyZXR Active Member Premium Member

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    Well I finally mustered the courage to pull the bottom end apart and found this ....

    22f3f2e857130bac355ade891977a774.jpg 4eb4584c3df6f18bcb1660242620310f.jpg

    Ahh man new bearings time . Everything else looks brand new except them . Pistons have little to no scoring on the skirts and no wear where the gudgeon pin live. Bores look barely worn. Crank is perfect from a visual inspection . Conrod little ends have no wear aswell. Oil pump looks new inside aswell. Gearbox looks perfect aswell . Mind you this engine has 56k kms on it .

    Also something to stay away from is Ali express valves . Tried them in the head and they're loose in the guides wtf? . Originals are worn and even they aren't sloppy so I'll live with the small groove they have and re use them.

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  6. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Yeah that main is a bit crappy.

    Can you do me a favour and check the oil pump drive shaft for play - it's behind the clutch basket. My C model had a lot of play in the shaft before it engaged. A hypothesis I discussed with a teacher at TAFE is that the shaft may have a 'U' in it to join the water pump shaft. If one side of it was broken, then the shaft would still engage but it would be loose... and that may be the rattle I was never able to solve.
     
  7. TonyZXR

    TonyZXR Active Member Premium Member

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    A U being a slot in the shaft where a pin slips in and the gear slides onto it then held on with a circlip?

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  8. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    No that part was OK. If the whole shaft is solid then the hypothesis is impossible. But if the water pump has its own dedicated shaft, and is driven by the oil pump shaft, there would be some form of mechanical linkage, ie a slot cut in one end and a protrusion from the other.

    If you have time, pull the oil pump / water pump apart and take some pics for me.

    Thanks.
     
  9. TonyZXR

    TonyZXR Active Member Premium Member

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    Ahh right . Nah the whole shaft is 1 piece and the water pump impeller threads onto the end of it . BUT the oil pump rotor is held onto the shaft with a pin aswell.

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  10. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    That is called an Oldham coupling.
     
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  11. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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  12. TonyZXR

    TonyZXR Active Member Premium Member

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    Makes alot of sense looking at the wear on the rest of the engine. Didnt know you can get the new ones coated? . Hopefully I can find some new genuine in the correct size

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  13. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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  14. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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  15. TonyZXR

    TonyZXR Active Member Premium Member

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    Done a bit more on the bike . All the gauges were cleaned and put back together . I made a new foam dampener. Headlights are also back on .

    526e945e7efdd53b91fc7a1006dad621.jpg
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    Also changed my switchblock to one that hasn't has the headlight switch snapped off .
    bc103bb3ce0883a081ba1efadc8ba157.jpg

    Got the last bolts re plated.

    016d9820979d081e3d6d9b2e1db15d2c.jpg

    Rear shock all reassembled. Probably should've replaced it but it's not leaking so it'll do for now


    3738de6b9fa14ddbf2fb6305beaefcb4.jpg 57b629f2299f5999df8c9b5986978198.jpg

    All the chrome was redone aswell. Bought a completely new brake lever to replace my B model one . Bought a new clutch lever aswell . Funny thing is they don't give you the the adjustment part 8ea5565fa167fedc88da3a29f1fc4059.jpg

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  16. Andych

    Andych Well-Known Member Premium Member

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    Loving the finish on everything... re-plated parts make such a difference... great job.
     
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  17. TonyZXR

    TonyZXR Active Member Premium Member

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    Sure does! I just like like seeing no rust haha

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  18. TonyZXR

    TonyZXR Active Member Premium Member

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    And there's bog everywhere

    69261b720418a547b0897bad354a4b0b.jpg

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  19. ShaneP

    ShaneP Well-Known Member Premium Member Contributing Member

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    I was just looking over this thread (the most recent 2 pages), all this beautiful work, as-new all over the place. And then that tank came up! . I guess that shows how much work you've done from where it started. Well done! It reminds me of what is required to do such work properly.
     
  20. TonyZXR

    TonyZXR Active Member Premium Member

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    Thanks dude . It was a pretty run into the ground basket case when I got it . Just thankful that it was mostly complete and wasn't bodged up too badly or in a bad accident .

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