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ZR250 Carburetor Bracket Removal

Discussion in 'Kawasaki 250cc In-line 4's' started by Mike Palmer, Nov 2, 2019.

  1. Mike Palmer

    Mike Palmer Active Member

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    Hi,
    I've had a lot of useful information from this forum and very helpful advice from members, so I thought I'd post a method I used to remove the stuck carburetor bracket bolts off my ZR250.
    I notice a couple of members have had to give up trying to remove their brackets.
    Maybe there is a better way to do this, but I havn't read of an effective method of removing the stuck bolts without the risk damaging the delicate carbs.
    I did try the traditional methods of soaking and light use of an impact driver, but the bolts were well and truly stuck. I havn't had a lot of luck with easy-outs with small seized bolts, they tend to snap and make the problem worse.
    In the age of disclaimers, heres my disclaimer! The following is entirely up to you, it worked perfectly for me, but I don't hold any liability for anything going wrong! Do follow safe practices and absolutely wear safety glasses when doing this, and watch that dremel disk.
    So, disclaimer over, I found this method to be reliable and safe for those delicate carbs (for me at least):
    1. Get a nice deep 7mm spanner.
    2. Hold the spanner on the bolt head and mark 2 flat sides into the head of the bolt, at right angles. Make sure you do this accurately. I used a fine permanent marker or soft pencil.
    3. With a dremel, carefully measure and cut the 2 flat sides into the head of the bolt, at right angles, so that the spanner fits nice and tight. Take your time and be careful not to dig into the bracket or any of the carburetor surfaces. It's not that hard, slow and sure is the way.
    4. Holding the spanner nice and snug against the bolt head with one hand, give the spanner a nudge with the heel of your other hand. It doesn't take much to get the bolt to move, usually with a little "crick" sound as the bolt frees from it's stuck state.
    5. Replace the cheesehead bolts with hex head bolts or allen bolts! I used allen bolts.

    That's it, hope the photos explain it better than I can write, it worked perfectly for me for all 8 bolts. I didn't find it necessary to cut more than 2 flat surfaces btw. Possibly there is a better method, but for me this was the only workable option I could find,

    Regards, Mike

    DSC_2512.JPG DSC_2514.JPG DSC_2520.JPG
     
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    Last edited by a moderator: Nov 2, 2019
  2. kiffsta

    kiffsta Senior Member

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    Hey Mike

    Nice work around and I am glad it worked for you, these are pain to get out as they use locktite on the screws, but I have a JIS bit for my impact driver, couple of whacks with a hammer and they generally come loose. I have had a couple where they wouldn't come loose and I used a long nose set of vice grips . As the screw has a fat mushroom head, you can use the vice grips to get a good purchase on the side and crack them loose that way

    Kiff
     
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  3. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Screw removing plier's come in handy too

    images?q=tbn:ANd9GcSrm7Zo3U77fycpEZEtcPjodI6nmKFF-dcNAFXCGZefcqygpLOg&s.jpg 913TZqv8cKL._AC_SL1500_.jpg
     
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  4. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    ZXR250's have the same bracket, I also had trouble with mine when rebuilding my carbs. I cut a slot in them with a dreamer and used a big flat blade screwdriver to remove them, with a little inox. If that fails just cut the heads off entirely and replace them with M6 hex heads or Allen screws.
     

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