1990 ZXR 250 cam chain replacement

[Shreddingus]

Hi all,

Just purchased myself a little zxr 250 thats in desperate need of some love and attention.

The cam chain was a bit noisy so I pulled out the tensioner and gave it a good clean and re-greased the bearing. The rattle went away, but after a deacent ride the noise came back with a vengance.

So after wasting my time doing an oil/filter change, it looks like I'm gonna have to replace the chain.

The unfortionate price tag of $400 (as estimated at my local bike shop) has lead me to the point where I feel that learning to do it myself may be better for the wallet and my bike knowledge.

If anyone would be willing to teach me or do it for me while I watch or even link me to an appropriate video or some other source of exactly how to do it, I would greatly appreciate it and be able to pay some moneys/beers.

But as I said before, I would like to head far south from that $400 mark...

P.S Im a broke ass student who has just had major wrist surgery because I crashed my preveous baby.. :(

Thank you all in advance for any advice/help you may provide!!!! :)

[Rhys]

I would adjust the cam chain tensioner again, they should be automatic but tend to stick, sometimes a few taps with a mallet will free them up

The cam chain is not to difficult to replace, there was a you tube video that showed how to wire the new chain to the old and pulled it thorough

Have you got the work shop manual ?

[FJRider]

It is most likely the tensioner that is the issue ... NOT the chain.

[Shreddingus]

I would adjust the cam chain tensioner again, they should be automatic but tend to stick, sometimes a few taps with a mallet will free them up

The cam chain is not to difficult to replace, there was a you tube video that showed how to wire the new chain to the old and pulled it thorough

Have you got the work shop manual ?

Thanks, I'll try cleaning up the tensioner again. Unfortionatly, the workshop manual for this particular model "1990 250a" does not exist.. I've been searching for it for weeks. But I did manage to get the Manual for the "C" model for which most parts of the bike are the same.

I was wondering, the bearing grease I used was purchased from super-cheep Auto, It didn't specify if it was Lithium based or not.. I wonder if that's what caused the problem?

[Shreddingus]

Ok, I've just taken out the cam chain tensioner again, cleaned it again and re-greased the bearing again.

Going into uni soon.. so will see how it goes and post the results... Still wondering if its the bearing grease im using..

[ducatilover]

ZXRs are known for tensioner and chain issues, as are the ZZRs of the era
I completely disassemble my tensioners and soak them/clean with kero.
I then inspect the teeth and measure the spring.
Grease, re-assemble and never have another issue :2thumbsup

I suspect you may have a shit spring, or slightly worn teeth on the ratcheting system

Or your chain's fucked, measure it between the links as per the C model manual
It's not a super hard job to change a chain anyway, from memory the chain runs down the RHS of the motor

[Shreddingus]

ZXRs are known for tensioner and chain issues, as are the ZZRs of the era
I completely disassemble my tensioners and soak them/clean with kero.
I then inspect the teeth and measure the spring.
Grease, re-assemble and never have another issue :2thumbsup

I suspect you may have a shit spring, or slightly worn teeth on the ratcheting system

Or your chain's fucked, measure it between the links as per the C model manual
It's not a super hard job to change a chain anyway, from memory the chain runs down the RHS of the motor

Ok, after pulling the tensioner apart again today and re-cleaning it in kero and re-greasing it. it still makes a hell of a rattle. Almost seems worse now haha.
So I'm starting to suspect that there is a loose bit of metal in the engine... souds too aggressive to be just the chain. :(

But I could be completly wrong.

Guess I'll have to pull it apart when I get some spare time... Gotta ride it every day to uni as I'm about 30kms away from the city lol.

Just hope it doesn't blow up on me!!!

[ducatilover]

Ask Kawasaki for the tensioner spring free length and the measurement for the chain links.
;)
YOu sure it's not an exh leak at the headers? They can make fucked up noises

[FJRider]

Guess I'll have to pull it apart when I get some spare time... Gotta ride it every day to uni as I'm about 30kms away from the city lol.

Just hope it doesn't blow up on me!!!

Just ask Akzle what happens when the cam chain lets go ..

If it's loose enough to worry about it .. it's loose enough to get the issue sorted. Continuing to ride it wont be helping.

[Rhys]

Cam chain 20 links

standard 127-127.36mm

service limit 128.9 mm

i should have the spring measurements as well, but can't find it at the moment

the tensioner should only be oiled with engine oil, if you put a new cam chain in it should be greased

[Shreddingus]

Cam chain 20 links

standard 127-127.36mm

service limit 128.9 mm

i should have the spring measurements as well, but can't find it at the moment

the tensioner should only be oiled with engine oil, if you put a new cam chain in it should be greased

Made a noob mistake and didn't oil up the tensioner... maybe thats causing it to stick. Will take it out and oil it as soon as I can. And thanks for the measurements!