ZX2R L Plater Project

G'day fellow 250ers.

I've been meaning to do a write up for a while now, but not much progress has happened since I got the ZX2R due working all the time and not being able to throw money at her due to other personal commitments.

But. . Finally got her running decent.

1st, managed to partially fix the timing chain rattle. Just used the tensioner off the spare I bought, there is still a slight rattle I can hear at certain rpm's though. Mainly when cruising. The spare I bought supposedly has a new chain so we'll inspect that and fit if it looks the goods we'll fit it.
The rattle was so bad the chain split the rocker after a 3hr flogging down the coast. Filled it with high temp silicone for the moment till I get a chance to swap the rocker over off the spare.

2nd, narrowed the hesitation problems down and got her running much better after some fresh oil, doing the plugs, swapping number 1 lead out, fitting new vacuum lines from the fuel tap to the Carbs and using some good old carbi cleaner. She starts much easier now and actually idles after removing the tiny washer off the idle cable which gave quite a bit more adjustment. More than I would've though. Idle still raises ridiculously as temps go up.
Will be tearing down the Carbs soon for a full rebuild, and getting some Top Gun 8mm leads made up.
She still hesitates and gurgles when I WOT (wide open throttle) it at around the 4-6k rpm mark but opens right up after about 7-8 right to the top. She seems to be running quite rich. Supposedly has bigger jets but don't know for sure yet. The vacuum lines from the fuel tap to the Carbs kept filling up with fuel, so I'm thinking running rich is partially due to the the tap diaphragm being buggered and fuel is running through that line into the Carbs making her run too rich. Maybe a tap overhaul or a replacement. I found a replacement on eBay, like $200. So I'd rather overhaul it if I can find the parts. Don't seem to have the part numbers for the tank in the parts catalogue in the resources section.

3rd, I cut up the rear tray and made a "custom" tail tidy and fit nice little led blinkers all round I'll be shaving down and bogging up the factory indicator holes to blank them out, then give her a spray job. Most likely black with matte orange wheels.

The Yoshi that's on it seems to be busted inside and spits flames sometimes, not sure if this is strictly due to running rich or the muffler being fkd. Or both. So I'll be getting a replacement soon but won't fit it till the Carbs are done.

In the next few weeks I will do the oil again, oil filter, air filter and the fuel filter. Then do the Carbs and muffler. Plan to get a little short GP pipe and low mount it just under my foot and heat wrap the whole exhausted system.

Going to get the valve clearances done eventually too as I doubt they've ever been done. With 51k km on it I'm sure they'll need doing.

Question about jetting. As she's running an aftermarket can and uni filter, would she need re jetting or would just tuning the stock jets do the job?

When the all this is done I will put her on the Dyno for a fine tune. Will most likely get one of those aftermarket CDI's too. Will give her a fresh drive chain (any suggestions as to which type?) go 1 tooth down on the front and 2 or 3 up on the rear before Dyno day.

1 down 3 up will give me about 3.5Nm extra, 1 down 2 up is about 3Nm gain and only 3km difference in top speed (166km vs 163km). Not much but I think I'll feel it on such a light bike. I'll lose about 25km top speed though I don't really need to be hitting speeds of over 160km on my L's.

Will be inspecting the clutch and brakes off the spare, hopefully they're in good condition and I won't have to buy new ones.

Other things I plan on doing:

-Tyga tail (maybe)
-Adjustable short levers
-Adjustable clip ons, 0-18° sweep. Depends on how my wrists feel after changing the position of the stockies, the position they're in now is to close to the tank and frame. I'm 6'3", hopefully moving them out/forward a bit will give me more room and take some weight off my outer palm and wrist.
-Rearsets (if I can find ones with a good position for my height)
-May look into running velocity stacks with an open airbox just for the fun of it.
-Racing cushion seat from japan.webike
-C model tank conversion, so to fit Tyga tail or C model tail..

 

Yeh I'm just glad to be back on 2 wheels. I only need her for a year or so then straight to a cibby thou I reckon, maybe a gixxer.

I still want to make her a good looking reliable bike, for myself and for resale value. I picked her up for quite cheap so I don't mind spending a bit money on her. But not going to go overboard.

 

Also in need of a new helmet as the brand new one my mate gave me because he accidently bought the wrong size doesn't fit properly now that I cut my long hair off.

I'm thinking this bad boy

Bell Star Carbon RSD Sway

http://www.revzilla.com/motorcycle/bell-star-carbon-rsd-sway-helmet

With the transitions lense which darkens and lightens itself

http://www.revzilla.com/motorcycle/bell-star-vortex-transistions-photochromatic-face-shield

And an orange race face

http://www.revzilla.com/motorcycle/bell-vortex-star-rs-1-race-face-shield

Any reviews ?

 

Another item to add to the list

Spider peak grips

http://spidergrips.com/spiderg/

 

Also be needing new tyres very soon, any good affordable and grippy suggestions? Something with a harder compound in the middle and softer on the outer maybe?

And will be needing to bleed the brakes. The fronts are very sticky.

Also, new cables all round I reckon

Probably update the gauge cluster to the C model one I have from the spare if it's plug and play. Hopefully so.

A steering dampener I found on japan.webike will definitely be on the list for those high speed corner hunting rides.

And possibly bar end mirrors if I can find ones I like.

 

Found a photo I took of the tail tidy

 

Thanks for the input mate.
I was actually thinking about after re reading my post and remembered they actually run ram tubes from factory. Plus it wouldn't be a simple clamp on application at all, adaptors would have to be made up. So Yeh nah fk that lol