Project: ZZR250

[deleted111]

Hi all,

A bit of background info:

I purchased a nice, tidy ZZR250 in July. All was well until a little accident, which resulted in cosmetic damage. All was then well again until the engine started making a funny noise from the top end which got worse and worse. The only reason I've took it on as a project myself, is because the big garages round here want an arm, leg, and some even want a kidney to do the work. My local backstreet mechanic just has a massive waiting list. I figured I need to learn this stuff sooner or later, anyway.

The bike is now off the road, and will be my winter project. I'm looking to learn the bike inside out and repair it myself. I've got a CG125 on the road still, so I'm not without transport.

A pic of how she stood before:

https://i761.photobucket.com/albums/xx254/stevelambert92/IMG20110819_006edit.jpg

I'm in two minds whether to restore it to the above condition, or 'fighter it.

Last night I set about stripping her down:

https://i761.photobucket.com/albums/xx254/stevelambert92/IMG20110926_003.jpg

https://i761.photobucket.com/albums/xx254/stevelambert92/IMG20110926_012.jpg

https://i761.photobucket.com/albums/xx254/stevelambert92/IMG20110926_017.jpg



If all is well and it's repairable/manageable then I'm expecting this to come together quite nicely.

Cheers,

Steve.

[pepperami]

LOTS and LOTS of pics with plenty of detail please

Get a knitting needle so you can point directly to things you`re trying to show us .

Pepperami will be watching you!
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I am the sum total of my own existence, what went before makes me who I am now!

[chris-red]

Don't fighter it.
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[Rowey]

[fatjames]

[Kickstart]

[fatjames]

Or a nice burn orange with black powder coat frame. The bike has a lovely shape.

[deleted111]

Comments taken onboard chaps, thanks. Whilst I'd like a fighter, I think I'd be best buying a bike especially for it.

Right, so far tonight I've got this far:

https://i761.photobucket.com/albums/xx254/stevelambert92/IMG20110927_002.jpg

Bolts 1, 2 and 3 are a potential issue. I haven't gone all Gung Ho on the thing, yet. However, my inquisitive nature got the better of me and I had a good prod at a few things, which led to me realising that aforementioned 1, 2 and 3 were VERY loose. 1 won't tighten at all, there's nothing for it to bite to. 2 will hand tighten but anymore and it's loose again, and 3 has just tightened up no problem.

Now, no doubt that would make the top end a bit more rattly, right?

ALSO. Do the cams and stuff need to come off the check the valve clearances? The two valves that I managed to get my fingers near had a gap of about half an inch .

Thanks in advance,

Steve.

[Kickstart]

Hi

Sounds like someone has stripped the threads on those. Helicoil time probably.

You should be able to adjust the valve clearances with the cams in place. You can't check them with the cams out, given that it is the cams that to a large extent affect the clearances.

All the best

Keith
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[pepperami]