1990 ZXR250 going for a complete rebuild!

[imdying]

Pics are good, we like pics

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!!!

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