1990 ZXR250 going for a complete rebuild!

[ZXCharlieR]

Hi Guys,

Thought I'd share the whole process with you as when the bike arrived, all I could think was strip, strip and strip some more!!

I have got more off her now than in the photos, I will post newer ones tomorrow but I am progressing nicely!!

The wheels will be going for a powder-coat next week, hopefully, and I'll be blasting the frame to get all the gunk off, she's not in too bad condition but I want her to look the dog's b's the day I take her for the M.O.T. (Vehicle inspection test here in the UK).

I must admit, I thought she'd be in better condition that what she is but there's only a few cracks in the fairing and it'll be going in for a full respray once the dollars are readily available!! going to take her original "Telefonica" colours as she should be, not that ugly paint-job that she has right now.

I do need some help as I posted here the other day, the custom made piston rings are NOT much of an option here so if anyone knows the exact dimensions (external bore, internal bore and thickness of each) so I can be more specific, or if anyone knows of a workshop there that makes them, would be very handy, I don't mind paying the expensive postage, just got to have them.

Apart from that, I can get pretty much the other parts needed, thank god, expensive but I think they'll be worth it in the end.

Will keep you all updated as and when things happen and if I do come across any parts for these bikes that you haven't, I'll post links just in case some UK bikers also need them!!

Cheers :2thumbsup

[ZXCharlieR]

Hi guys,

Here's today's progress:

I started with the subframe to get it ready for it's sand blasting but lo and behold I came across the famous last screw that just wouldn't shift, so I had to leave the rear fairing plastic and protective plastic on it until I get my easy-out kit that comes tuesday, so, brakes on until then but I have progressed and I was amazingly surprised at ALL the bolts coming off the headers, wow, that saved me a lot of grief!!!

The one thing that made me worry was seeing some really ugly gunk in the water tank, it looks like part of a seal, something went wrong somewhere along the line eh...??? lmfao!!! oh well, onward and upward

Here's some of the photos:

[ZXCharlieR]

Here's the others:

[ZXCharlieR]

The last for today!! Heheheeeee!! :beer:

[R6_kid]

When did Telefonica ever sponsor Kawasaki? Correct me if I'm wrong but they only ever sponsored Honda and Suzuki as far as I'm aware.

The current colour scheme is what it SHOULD look like if you are going to keep it original. The link below shows the original Kawasaki green/white/blue paint they came out with in 89/90, there is also a blue, and a red equivalent too.

[ZXCharlieR]

When did Telefonica ever sponsor Kawasaki? Correct me if I'm wrong but they only ever sponsored Honda and Suzuki as far as I'm aware.

The current colour scheme is what it SHOULD look like if you are going to keep it original. The link below shows the original Kawasaki green/white/blue paint they came out with in 89/90, there is also a blue, and a red equivalent too.

Hi mate,

Not to judge your knowledge of bike history but we refer to the "Telefonica" Kawasaki due to their colour scheme in the late 80's early 90's, not for their sponsoring, you see, Telefonica had, at that stage in modern day life, a Green, White and Blue logo hence the reference.

I lived in Spain for 18 years and if you refer to any ZXR in that era, you would ask if you "had the 'Telefonica' paint scheme or ... what other colours are there?", very famous bike and even more famous colour scheme!!

Here's a link for you to see:

http://www.google.es/search?sourceid=chrome&ie=UTF-8&q=simile#sclient=psy&hl=es&source=hp&q=telefonica+zxr&aq=f&aqi=&aql=&oq=&pbx=1&bav=on.2,or.r_gc.r_pw.&fp=f068e0c5e7ca2203&biw=1280&bih=709

It may just be a Kiwi thing that you refer to it differently.

Cheers

P.S.: Link?

[R6_kid]

http://www.motorcyclespecs.co.za/Gallery/Kawasaki%20ZXR250R%2090.jpg

So what you were meaning. No one in NZ would ever call that "telefonica"... that's classic early 90's Kawasaki :2thumbsup

[Chancebmx25]

should look awesome when complete. give it a one piece tail and digital tachos. will be awesome. kit it out with xenon lights and what not and that thing will be dubbed lol.

[macros87]

Always nice to see people putting up their ZXR250 work. I am on my second 1990 zxr250, other than the cam chain needing to be changed every so often and the regulator rectifier having a nack for burning out on you they are awesome bikes.

Out of curiosity why a zxr250? when i look for parts online I barely ever find any out in the UK, tons of zxr400 parts though... its gota be pretty rare over there.

[ZXCharlieR]

Always nice to see people putting up their ZXR250 work. I am on my second 1990 zxr250, other than the cam chain needing to be changed every so often and the regulator rectifier having a nack for burning out on you they are awesome bikes.

Out of curiosity why a zxr250? when i look for parts online I barely ever find any out in the UK, tons of zxr400 parts though... its gota be pretty rare over there.

I originally wanted a CBRR250 due to the complete and utter rareness factor, they are like gold dust here but the ZXR are rare, just not AS rare, so I opted for one when I saw her for sale on ebay.

I knew there were problems with her but I didn't think there'd so much to do on it, then again, I do love a good challenge!!!!

There are almost NO parts here in the UK for this bike, have to have the rings custom made from some guy in Bradford, gaskets are not too much of a problem as Corby Kawasaki can accommodate quite well!

This is my first ZXR250, I chose this over the CBRR as I think it actually looks sexier but the maintenance is a bit higher from what I understand.

I do prefer the CBRR's sound but you really have to be a patient man if you want one as they appear once in a blue moon.

[ZXCharlieR]

should look awesome when complete. give it a one piece tail and digital tachos. will be awesome. kit it out with xenon lights and what not and that thing will be dubbed lol.

Hi mate,

I'm not going to mod her in any way possible, I like bikes as original, I do like your idea but I just think modding would ruin it's charisma, I love standard bikes, specially when they are classics like this one!!

Cheers for the thought though!!

[imdying]

There are almost NO parts here in the UK for this bikeConsider very carefully eBaying it and getting a ZXR400 then.

[ZXCharlieR]

Consider very carefully eBaying it and getting a ZXR400 then.

And where would the fun be in doing that?

[imdying]

And where would the fun be in doing that?That's the point, ride both and you'll see where the fun is :yes:

[ZXCharlieR]

That's the point, ride both and you'll see where the fun is :yes:

Hi mate,

Can I ask, as per my intuition tells me, how long you've had that 400 for?

I can appreciate what you are saying but I have to say, after 30 years of biking, first dirt bikes then legal road bikes for the past 20 years, I have found that this is just one of those out of the blue situations that I had take advantage of, how many of these bikes are left and how long are they going to last?

I have had the lot from Gixer Slabsides to Vespas and I just love any bike that I find is rare and collectable, if I would permit myself, I would never have sold any of the bikes I have had and become the Jamiroquai of bike collectors.

The one I am most gutted about is my GPZ750 Turbo I had back in 93, now that I SHOULD have kept, gutted!!!

I am currently looking at a Matchless G3, although my heart says "Buy it", I have to stick to one project at a time.

This bike is going to stay with me for years to come and she'll be extremely well looked after, I am not in it for the fun of just riding, I am in it for the fun of rebuilding and enjoying everything about bikes, not just cos one is faster than the other.

Don't take all this the wrong way at all mate, I love all bikes and have, possibly, tried all the bikes I have ever loved, my ideal bike is actually the 1920's Indian Scout, now you Kiwis should be more than familiar with that bike!!

I hear what you are saying fellah but I couldn't care less if I am leading the pack or just plodding on happily behind!!

Cheers!

[macros87]

I originally wanted a CBRR250 due to the complete and utter rareness factor, they are like gold dust here but the ZXR are rare, just not AS rare, so I opted for one when I saw her for sale on ebay.

I knew there were problems with her but I didn't think there'd so much to do on it, then again, I do love a good challenge!!!!

There are almost NO parts here in the UK for this bike, have to have the rings custom made from some guy in Bradford, gaskets are not too much of a problem as Corby Kawasaki can accommodate quite well!

This is my first ZXR250, I chose this over the CBRR as I think it actually looks sexier but the maintenance is a bit higher from what I understand.

I do prefer the CBRR's sound but you really have to be a patient man if you want one as they appear once in a blue moon.

I considered a cbr 250 both times I was in the market for a bike, but the zxr is just a nicer fit for me, its bigger, the cbr feels quiet cramped to me, im 6 2 tall so while I knew it would be cheaper to maintain i just couldn't not get a zxr.

you like the cbr's sound better? am I wrong to believe that carbon fiber exhaust you have on it is a straight through can? because the difference between a zxr stock exhaust and a straight through one is night and day, it is much better, even in comparison to the cbr which sounds far too much like the sewing machine cliche in my opinion.

[ZXCharlieR]

I considered a cbr 250 both times I was in the market for a bike, but the zxr is just a nicer fit for me, its bigger, the cbr feels quiet cramped to me, im 6 2 tall so while I knew it would be cheaper to maintain i just couldn't not get a zxr.

you like the cbr's sound better? am I wrong to believe that carbon fiber exhaust you have on it is a straight through can? because the difference between a zxr stock exhaust and a straight through one is night and day, it is much better, even in comparison to the cbr which sounds far too much like the sewing machine cliche in my opinion.

Hahahahaaa, I like the simile!!

I just like the smoothness of the engine and the lack of rattling sound that comes from the engine whilst riding, kwakas are noisy, Hondas are just smoothies!!

The can I HAD on the back of mine certainly did sound good but it has sadly left us now, I'm going for a Scorpion Chrome next as it's better looking, but by all means, I hear where you are coming from!!

Cheers buddy!

[imdying]

This bike is going to stay with me for years to come and she'll be extremely well looked after, I am not in it for the fun of just riding, I am in it for the fun of rebuilding and enjoying everything about bikes, not just cos one is faster than the other.I totally know what you mean, I too enjoy building them as much as riding them. However, the only thing the ZXR250 really lacks is just a bit more poke... you have to absolutely rape the crap out of it to make it go anywhere; it's just a torque issue. That's kind of fun for a while, but it does not take long to tire of waiting for the sky high redline to front up. Sure you could lower the gearing to get it there a bit quicker, but then you'd have completely neutered the top end.

The ZXR400 has all the charms of the 250, just with that extra poke. It's also easier to find parts for, so if you're going to dive knee deep into something that will likely such a few thousand pounds down, it might be worth considering changing before you start to spend. It's still a grey, but people have raced them against 2 stroke 250s for years, so there is plenty of tuning knowledge around, and a lot more places that can provide you with spares. For example, you won't have trouble finding pistons for the ZXR400, even oversize. Hell you can even get stroker cranks for them!

The biggest reason there won't be any ZXR250s around in 20 years time is because the 400 was basically a superior unit for not a lot more cash. These days, no more cash.

[imdying]

This seems cheap and might interest you:

http://www.kiwibiker.co.nz/forums/showthread.php/125524-ZXR250-DID-performance-exhaust!?highlight=zxr250

[ZXCharlieR]

I totally know what you mean, I too enjoy building them as much as riding them. However, the only thing the ZXR250 really lacks is just a bit more poke... you have to absolutely rape the crap out of it to make it go anywhere; it's just a torque issue. That's kind of fun for a while, but it does not take long to tire of waiting for the sky high redline to front up. Sure you could lower the gearing to get it there a bit quicker, but then you'd have completely neutered the top end.

The ZXR400 has all the charms of the 250, just with that extra poke. It's also easier to find parts for, so if you're going to dive knee deep into something that will likely such a few thousand pounds down, it might be worth considering changing before you start to spend. It's still a grey, but people have raced them against 2 stroke 250s for years, so there is plenty of tuning knowledge around, and a lot more places that can provide you with spares. For example, you won't have trouble finding pistons for the ZXR400, even oversize. Hell you can even get stroker cranks for them!

The biggest reason there won't be any ZXR250s around in 20 years time is because the 400 was basically a superior unit for not a lot more cash. These days, no more cash.

Gotcha!!! I got it because it was rare and dirt cheap, I mean night out cheap, a meal with the Mrs and a good night on the town would work out more expensive, so no more dining the Mrs!! LOL!!!

I do like the 400's but it's like I said before, it's not the power I am after, if it were, then I would have bought a Fireblade or something relatively beefy but this is just a new project and I have been dying to get my hands on one of these little screamers for years, just fell into my lap and I just couldn't resist!

You see, all through my biking years, nor one of my friends nor I have had the opportunity to have one and we grew up in that era looking for them and dreaaaaaming of having one, 19,000 revs dude, OMG!!! but nothing remotely like this came our way, now I have one and all my mid 30 yr old friends are soooo envious, the conversations we've had over the NC30's also, WOW!!!

All I am saying is that it's just one of those things that bring back the nostalgia of our early days as bikers, we all had RGV's, NSR's, KR1s's, etc, you get the picture? we HAD the power just not the redline and it was our dream!!

Thanks for the advice all the same, I do appreciate it but this is going to be on collector's monthly when I'm too old to even walk!!

Cheers!!

[imdying]

You see, all through my biking years, nor one of my friends nor I have had the opportunity to have oneHey you didn't miss much, a lot of my friends had these or CBRs. In fact a girl I dated for a while had a ZXR250A like this, she loved it :yes:

[ZXCharlieR]

Hey you didn't miss much, a lot of my friends had these or CBRs. In fact a girl I dated for a while had a ZXR250A like this, she loved it :yes:

I just think it's all the mental-wanking we were doing as 18 year olds whilst thrashing the nuts off our 250 oil-burners, great nostalgic trip though, even more fun 20 years later!!! I got goose-bumps now! lol!!!!

[ZXCharlieR]

This seems cheap and might interest you:

http://www.kiwibiker.co.nz/forums/showthread.php/125524-ZXR250-DID-performance-exhaust!?highlight=zxr250

They look weird to me, but hey, aluminium, light as hell.

I am getting new stainless on mine as my Uncle makes stainless pipes and he mentioned something about them being free for me ;), we all know that the family is there to be abused, just like friends!! :killingme :killingme

Appreciate the though and the heads up though mate, much appreciated!

Cheers!

[ZXCharlieR]

Hi again guys,

Here's my progress to date:

After some days waiting for my new tools to arrive, I have resumed work (stripping), here's some more photos of my progress:

[ZXCharlieR]

And some more...

[ZXCharlieR]

And some more ...

[ZXCharlieR]

Yet some more ...

[ZXCharlieR]

More photos of other's botch jobs ...

[ZXCharlieR]

Here's the last for today, will post some more tomorrow!!

[ZXCharlieR]

Here's my 2 cents:

Loads of carbon build up on all the valves, haven't tested nor taken them out yet but I the build up is somewhat normal.

The spark plugs are weirdly clean on 2 and oily as hell on the other 2.

Piston 1 is weirdly clean, hence no firing and some play
Piston 2 is heavy with build up
Piston 3 is the weirdest one of all with a surprisingly clean top
Piston 4 is again weird with some play

Out of all of them, Piston 2 is what I would say "normal", I mean, after 41,000 kms, I would expect the build up it has.

Sorry for the repeat of some of the photos, my fault!!

As for the valves, horrible build up but again, what can be expected after 41,000kms? I am worried about the state of the spark plugs though, 2 are very clean and the others are extremely oily.

When I opened her up, petrol poured out of the sump mixed in with the oil so I think that is going to be my main task tomorrow, take the sump off and give it the clean of it's life but I am dreading it due to what I think I am going to find in there.

Anywho, feel free to give me some feedback!

Cheers guys!!

[imdying]

Pics are good, we like pics :yes:

Be interesting to see how the seats and stems are, and what the clearance on the main/big ends are on a high revving 250 after 41000kms.

[ZXCharlieR]

Here's some more pics of what I have done today, just stripping and cleaning at the mo but will soon be getting down to some nitty gritty!!

The piston rings and pistons were fine after all, it was the head gasket that was shot, but I thought "Whilst I am here, might as well get on and give it new gaskets, seal it up nicely and then see if she runs"

I have done a leak-down test on the pistons and valves and there is no leak what so ever!!! so all good there then!! just the head gasket was shot to bits!!!

Here's the photos fellahs, oh, and ladies!!! :innocent:

Cheers!!!

[ZXCharlieR]

And some more!!

[ZXCharlieR]

And yet some ...

[ZXCharlieR]

Yawn ... and some!

[ZXCharlieR]

Here's the last of them for today!! Be posting some more tomorrow as I will be carrying on.

Cheers peeps!

[racefactory]

41,000km is not much at all for a zxr250. There are heaps around going hard with nearly triple that. Be surprised if you found any true worries as far as the engine goes. Carbs is another story though...

[Chancebmx25]

41,000km is not much at all for a zxr250. There are heaps around going hard with nearly triple that. Be surprised if you found any true worries as far as the engine goes. Carbs is another story though...

factoryy!!

[ZXCharlieR]

Hi again guys,

Here's some more progress, I did a leak test on the valves and cleaned the other pistons, now, to my horror I have found a, in my opinion, seriously knackered piston and a leak in the valves, the 2 don't coincide as they are on different cylinders but I can see now why cylinders 1 & 3 were not giving compression readings.

Here's some more photos:

Cheers!

[ZXCharlieR]

And some more as usual ...

[malysiak]

hey i have just done something similar but goofed up with two things, first of all i didnt line up the forks with the gears properly when i put the two halves back together, what a dumb ass :\ the other thing which im struggling with more is the cam chain. now i am using a zxr250A manual and have a 1993 zxr250 C, and i put the chain back on teh crankshaft sproket all good, however got confised about how to get it onto the cam sprockets, anyway after a while i got it, pulled tension onto the exhaust side of the chain, and got the 29 links between the EX and IN on the two sprokets, then let the tensioner out to put tension is the chain. anyway when i started the bike up for the first time i am sure the cam chain is rattling at about 4000 rpm.
i was wondering if you could please tell me any technical specs i will need for this that i may have got wrong, and the process you went about getting the cam chain on the sprokets on your bike.
your help is greatly appreciated