zzr 250 wtf moment

[cam|mac]

Hey crew,

Long time crawler, first time poster here.

I've just brought my 2nd ZZR250 recently. I'm a firm believer in doing fluids first when buying a new vehicle. Who better to trust than you when doing maintenance stuff?!

Anyways, I'd done the oil & filter change on the ZZR. Thanks to Mr Kawa for makin that a walk in the park! The only thing I'm having a problem with is the coolant system... It's PISSING out coolant from a wee pipe from what looks like the thermostat. Link --> http://motoconnection.com/used-pre-o...50-engine.html

I can see the "in & out" pipes, but I can't figure out the small one coming off the side. I can see the pipe heading off from the top of the head & the exit pipe leading off to the rest of the coolant system, but the coolant is making its escape from the small 'other' tube.

I've had a look at the Kawa EX250 Wiki but its not a whole lotta help. It's tried to run itself dry because of this, luckily it doesn't seem like I've done any major damage...yet

So, any thoughts on what it could be? Being a recent fella to the scene, I'm more than happy to offer beer for the man (or sheila) who can piont me in the right direction to getting it fixed. I really just want to go for a ride again!

I'm hoping someone else is had this problem before. It's a right bastard!

Cam.

[NinjaNanna]

Might be a dumb question but - on your bike is the other end of this pipe connected to the nipple located on the corner of the rocker cover as shown in Image 3 of 8 from the link you attached?

Also I've know idea what the answer is but I'd be checking to see whether that little hose is meant to be a low pressure coolant hose or a vacumn hose? If its meant to be a vacumn hose then your thermostat is bung and needs to be replaced.

[cam|mac]

Might be a dumb question but - on your bike is the other end of this pipe connected to the nipple located on the corner of the rocker cover as shown in Image 3 of 8 from the link you attached?

Hey Ninja

Nope, it's not attached to anything. The pipe is only only a couple inches long at the mo & has a split in it. It must've sheared off somehow. I know it has to attach to something, I just dont know what!

Also I've know idea what the answer is but I'd be checking to see whether that little hose is meant to be a low pressure coolant hose or a vacumn hose? If its meant to be a vacumn hose then your thermostat is bung and needs to be replaced.

I like your idea there. I suspect the thermo might be bung (obviously something is!) but do need to know where mystery hose goes so I can get the bike purring again.

Any other ideas out there?

[nodrog:Me]

if you are taking about the pipe that comes out of the silver rectangle on the rocker cover, and goes into that round black solenoid, thats the kleen air system. If you have water coming out of there, you have some problems.

[NinjaNanna]

Haven't you now answered your own question, look closely at the photos in the link you provided, if your's is too short and shows signs of being damaged then the logical course of action is to remedy that.

I would not jump to the conclusion that the thermostat is bung when you have a hose leaking fluid that's simply not connected properly.

[cam|mac]

Here we go!

I just need to know where the free end of this pipe is supposed to reside. Ninja, I completely agree I need to remedy this! I'll head out on Saturday & get everything back up & running once I know where the pipe is supposed to end up.

All the help is appreciated. Once I've got this sorted, then its only brake pads & fluids to go then I'm happy to get a few more miles under my belt. Cant wait...!

[The Singing Chef]

Here we go!

I just need to know where the free end of this pipe is supposed to reside. Ninja, I completely agree I need to remedy this! I'll head out on Saturday & get everything back up & running once I know where the pipe is supposed to end up.

All the help is appreciated. Once I've got this sorted, then its only brake pads & fluids to go then I'm happy to get a few more miles under my belt. Cant wait...!

If you ever need spares of anything, I have a whole bike in pieces at the moment. Good luck on getting it fixed mate

[nodrog:Me]

Here we go!

I just need to know where the free end of this pipe is supposed to reside....!

wouldnt it be where you have drawn the arrows?

[imdying]

Can't see fuck all in that shitty picture, so stabbing at go have a look at your coolant reservoir bottle. Should have two hoses, one an overflow, one back to the cooling system, probably the thermostat housing.

[Slyer]

As someone who has recently fixed up a faulty cooling system on a ZZ250 I think I can claim to have some knowledge about it.
Those pictures you've shown won't very helpful as they are for the new Ninja 250, the ZZR250 has the same engine as the older 250, GPX250.

Up near your right handlebar should be the radiator cap, just below this there will be three tubes: The small tube runs over the top of the engine and to the bottom nipple of the coolant reservoir under the bike's left hand side cover, there should be another tube that runs from here over the bike and down to the ground, this is the overflow tube.
The next will be a wider tube that runs out sidewards from the radiator cap holder thing over the top of the engine, hooks up to the thermostat and from there to the top of the back of the engine. Looks like this: http://www.maxsalvage.com/media/2c/a...b051f13b_m.JPG
The final wider tube runs from the bottom of the radiator cap holder and runs to the top of the radiator.