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Project Tony's ZXR250s

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

  1. TonyZXR

    TonyZXR Well-Known Member

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    Soo after fixing the fuel tap and electrical system it's not running the best . I have a feeling a bit of crap may have found its way into one of the carbs:(. In the meantime I thought eh might aswell install these finally before i pull the carbs off .
    20200821_153705.jpg
    4 ninja 300 coils and a small coil loom from a 2004 cbr600rr . Modified the harness to run the coils in series and installed them with a new set a sparkplugs while it was apart after I verified that it ran. (Old plugs were 3000kms old)
    20200823_173743.jpg
    Looks like it was running decent with cylinder 1 looking a tad lean . ( also they look alot darker in the photo) .

    20200823_173005.jpg
    Coils all installed and had to clearance the radiator fan slightly . Starts extremely easy susprisingly . Now to give the carbs a good clean and hopefully it'll run like normal again
     
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  2. TonyZXR

    TonyZXR Well-Known Member

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    Pulled the carbs apart and as usual they're full of fine rust , will have to do a tankliner in the future. Carbs all clean and rechecked the pilot screws 2.75 turns out. Started it up and checked the balance and cylinder 1 was pulling more air than the other 3, might explain why that plug was a tad lighter than the rest. Took it for a ride and wow what a difference . Easy to start and feels extremely smooth right to redline.
     
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  3. TonyZXR

    TonyZXR Well-Known Member

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    So unfortunately this happened yesterday. Combination of everyone suddenly braking . Me panicking and also being slightly distracted.
    20200905_150027.jpg

    Nosecones destroyed, muffler is scraped, brake lever broken , handle bar scraped, front gaurd scraped and side fairing scrapped and cracked aswell as all the brackets bent plus a fair bit more. Missed the tank and rear end atleast. Pretty bruised and sore today and my ego's hurt but we never think of that
     
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  4. TonyZXR

    TonyZXR Well-Known Member

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    So did a bit of work on the crashed bike yesterday. Installed the new brake lever, repaired the scarred muffler and repaired the cut oil pressure switch wire and charged the battery up . I also found the charging system fault . I wish i took a photo. For a long time I noticed a fine white sand on top of the carbs and underside of the fuel tank. Thinking nothing of it I removed the reg/rec and lo and behold I found the charging system fault. I noticed the black potting material on the underside felt a little bit soft and it wasn't sitting level. The ceramic material inside the reg/rec had completely disintegrated ! That was the reason it wouldn't charge at idle . Replaced the reg with a spare, started it up and now it's charging properly which is a relief. Also while it was running I noticed cylinder 4 had a cold exhaust pipe so the carbs are going to need attention.
     
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  5. ShaneP

    ShaneP Well-Known Member

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    ZXR carbies service intervals: regularly. Bummer
     
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  6. TonyZXR

    TonyZXR Well-Known Member

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    Doesn't help when you have a rusty tank too hehe. Gives me a chance to try out @maelstrom s new seals
     
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  7. TonyZXR

    TonyZXR Well-Known Member

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    So the side fairing and nose cone are finally all repaired. Bit of a headache but atleast its all done. Bit of high fill on the repair areas and it's ready for paint :) 20211010_140131.jpg
     
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  8. TonyZXR

    TonyZXR Well-Known Member

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    So I've decided to get back into this finally. Starting with the battery. The old lead acid one was completely rooted from the broken reg/rectifier. To the point where the positive terminal had melted out of the battery .
    20220618_162008.jpg
    Bought a new ssb seal battery for it . The terminals are on the side but that's a small sacrifice for the gain. Much higher cca the last one!

    Now seeing as the bike had been sitting the ol carbs had reared their ugly head once again. A good clean out and it runs once again. Checked the balance on them aswell just because I was there. Runs great again!

    https://youtube.com/shorts/JW-ZS3vnyv4?feature=share

    Next up was the fuel tank. After cleaning the carbs so many times from the rust in the tank I decided it was time to use a tank sealer. I used the KBS Coatings kit which is still holding up nearly a year later and the fuel filter and carbs are nice and clean luckily.

    And lastly it was time to finally paint the panels .
    20230423_174917.jpg
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    It's not perfect but its arguably better than the last time it was painted .
    Couldn't resist and had to take it for a spin around the block.

    I still need to replace some hardware that was damaged , put some decals on, fix the warped front brakes. And replace both tyres before it gets historic rego.
     
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  9. TonyZXR

    TonyZXR Well-Known Member

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    Bit more work on the ol girl . Finally wrapped the nose. Was supposed to do it when it was finished the first time. What's everyone's thoughts on it ? I'm a bit 50-50 on it .

    20230426_175913.jpg
    20230426_192648.jpg
     
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  10. TonyZXR

    TonyZXR Well-Known Member

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    Well the big brake upgrade is almost finished would've been done if I didn't lose a piston seal...
    20230430_152648.jpg

    Seeing the temperature gauge is a bit of a challenge now. May have to run the original reservoir .
    20230430_152205.jpg
     
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  11. TonyZXR

    TonyZXR Well-Known Member

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    Had a day off work today so I got a few things done. She's registered now under Historic registration.

    The insulation on the side fairings was always missing so I made some templates and cut some out and glued them on. It looks fairly good , hopefully it'll stop the old brittle plastic crumbling from the engine heat.

    20230502_184142.jpg 20230502_230839.jpg
     
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  12. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    What about going with an all-in-one setup?

    upload_2023-5-5_17-39-14.png
     
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  13. TonyZXR

    TonyZXR Well-Known Member

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    That's a good idea but I've already put a seal kit into the zxr750 one . Kinda don't want to spend more money

    And on the note this is reason why

    20230505_193412.jpg

    Can't seem to find anything other than alpha 14s anymore. I was contemplating using a ninja 250 wheel but by the time I priced it up it would've been the same.

    Before I have the tyres fitted I needed to paint a spare front wheel I have because the one on the bike actually has a pretty nasty buckle in it.

    20230506_152256.jpg

    20230506_152223.jpg

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    And as usual I couldn't help myself, after seeing the front wheel shining I've decided to paint the spare rear wheel I have too ‍♂️


    20230507_193452.jpg
     
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  14. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    I think it looks damned fine and it ain't easy getting smooth matched curves with tape as you've managed.
     
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  15. TonyZXR

    TonyZXR Well-Known Member

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    Well as usual I couldn't help myself and painted the rear wheel too, it was heavily corroded compared to the front one.

    20230509_170243.jpg

    Meanwhile I thought it would be best to pull the rear suspension apart, inspect and grease it.

    20230511_122736.jpg

    Turns out the last owner had mucked around and left one of the bolts loose in the suspension linkage :confused: And I rode it for a year like that.... that would explain the knocking. Note to self not to trust anything before I get to it.:oops:
     
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  16. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Hey Tony, you probably already know this, but that buckle in your rim can be rolled out. I had one done by a guy in Melbourne. He doesn't like doing them if the buckle is near the spokes, but yours looks like it should be fine.

    upload_2023-5-11_18-19-46.png
     
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  17. TonyZXR

    TonyZXR Well-Known Member

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    Yea for the money it just didn't seem cost effective. FYI if anyone wants the old set they'll be for sale . I've also got a frame but the mount where the gauge bracket bolts on has been cracked off and re-welded on . Need the space
     
  18. KiwiMat

    KiwiMat Well-Known Member

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    I use Aldertons to fix my wheels in Sydney. He does a perfect job every time.

    Screenshot_20230518_185527_Samsung Internet.jpg
     
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  19. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    He did my FZR rim. First class job and reasonably priced too


    Sent from my iPhone using Tapatalk Pro
     
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  20. KiwiMat

    KiwiMat Well-Known Member

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    and.... he always removes the tyre to fix the rim and puts the tyre back on and balances it..... so i have used this opportunity to change tyres in the past too.
     
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