1991 ZXR250C Resto

[kessen]

Hello PSBers,

Thought it was time I posted up a thread on my ZXR250C restoration project I started at the beginning of the year. Thanks for taking the time to view and comments are much welcome.

Background:
Bought the bike off a good friend who had it sitting in her shed for around 2 years. Was in pretty bad shape and not running, so one day I finally bit the bullet and went round with a trailer and bought it off her.




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Beginning weeks:
I had a feeling I was going to restore her but I wanted to first see if I could get her running. That way I'd also know if I liked the ride. So away I went with heavy research, learning a few words in Japanese before discovering the incredible magic of Google Translate and finding out a lot about the bike. Numerous posts on PSB also revealed a few gems of information. Finally built up a few sources and started tearing the bike down. Got it running after discovering the air filter was shot, there weren't any carburettor o-rings and the battery was kaput. So I bought new o rings and a battery. Air filter was a bit harder so in the end made my own (I made up a template if anyone else wants it).







So I got it running and rode it around. The rear shock was completely gone and it would bounce you off the bike if you weren't careful going over railways etc. But I loved riding it, so easy to throw around and the engine was still strong. Lacking in the sound department but then again it's a stock exhaust. Riding it around I discovered the rectifier was also shot which made for an interesting ride..er..limp back home. Luckily had my mate handy with jump leads.

I subsequently dismantled the entire bike, taking everything apart. I organised the frame to get powdercoated, the fork tubes anodized, all other alloy bits polished (e.g. rear sets, pegs etc), all bolts cleaned and zinc plated. New chain, sprocket, plugs, filter were on order. Also ordered a tyga fairing kit. I wanted a completely modern looking bike, well that and the old fairings were damaged. Everything was cleaned and re cleaned. The engine head was polished and the engine sprayed black. The forks were overhauled (MASSIVE shout out to Marty here. A real genuine man who's both highly capable and willing to give a hand.) and given new oil. Brakes were also overhauled by Advanced Brake Remanufacturers in Port Kennedy (the best brake place in Perth I reckon. Speak to Kelvin there, he's a great dude). Seats were re upholstered, exhaust headers given a light blast and painted silver, exhaust polished up to a decent shine and new gaskets put in.













I've decided on a matte black theme




Anyway tonight was the night I got her running after months of inactivity (probably the reason why I decided to post now). A very rewarding experience I must admit. Now just on to the electrical system. The tyga kit comes with everything but rear indicators so now looking at how odd the stock rears would look on the new kit I've decided to looks for some after market ones. Once that's done just re working the flasher relay so I have some decent flashing frequency and she should be good to have her fairings test fitted. After that looking at painting her and hopefully get her riding around a bit next week.

Also in the pipeline are new tyres and a carbon exhaust. Seeing my mate's new roo muffer makes me want one so bad.

What do you all think? (please excuse the 'YEAHHH' - I was filming on the phone and that's my message tone haha also yes I do realize the bulb is out)
http://www.facebook.com/v/10150192896185855

Thanks for reading. Updates to follow.

Sherman

[bobbyhavok]

Nice work mate, long live the ZXR2R's

[kessen]

Thanks =)

So some more progress:

Test fitting some fairings







Testing the tail lights


Another decal design? Ignore the jap writing I've vehemently decided against it but perhaps gold or white? Suggestions?

[bobbyhavok]

Oh nice! Those new fairings really look the goods!

[Frogger]

looks cool, i like those tyga fairings except the mirrors. they look out of place.

[Twigs]

I love the white!! Very nice, great with the Matte Black too. Gold and White....hmm... I guess you can only try and see how it goes
I'm sure it'll look ace once your done

[Jacko]

Nice looking build. Subscribed.

[datsikk]

looks friggin awesome.

that matt black scheme looks good

[kessen]

Thanks guys. I'm getting so close to finishing I'm wanting it too much and so I've decided to ease up a bit and not expect to have everything done in one go. Plus with exams next week my focus needs redirection.

Tell you what the headlights were a @#$*( to get in and fix.

Frogger - yeah I think the headlights are a bit odd too, being so rounded compared to the rest of the bike.

Twigs - I was thinking white but the 'R' in ZX2R in red? I've got a decal jpg that I'll vectorize and hopefully be able to take it to one of the vinyl/decal sponsors on PSB and see what magic they can conjure. A nice gold though could also set it off too =\ maybe two sheets? haha

I've just ordered a 2pac paint kit by SEM called 'Hot Rod Black'. Anyone else used this before? Apparently comes up as a real good strong matte finish. I think I've seen a few on some show car silvias but have never seen one on a streetcar (i.e. next to me at the lights) so I'm not sure as to how 'durable' it will be.

I'm also contemplating ordering a pair of Oxford rear indicators. At the moment I've decided on the 'Arrow' type; black with clear lens. Halogen globe too. I've yet to see a really good LED indicator but looking at the 'honeycomb' lens on the Oxford Saturn indicators I can't help but hope that it help mitigate the 'uni-directional' brightness associated with LEDs? Has anyone got any?

Not much progress today though unfortunately...other than the headlights being in the front fairing now...

Oh if anyone has a Ninja 250R tinted screen floating around they'd be willing to sell? or say swap for a clear one?

[Twigs]

White and red always look good together- but you can always try the gold and white together and be different.
Have a look around or maybe even look at past Kawak's colour schemes and use one of the Kwaka colours for the decals to still give it the feeling of "Yes, it's a Kawasaki- An Awesome one!" Just an Idea I thought of then
I'm also assuming you'll be getting new seats made up due to the wear and tear visible on the old ones?

[kessen]

Yeah the rider's seat has already been done in a black vinyl again. Probably can't see it too well in the pictures but I'll get a photo up of it soon just to show. Haven't bothered with the pillion seat though because a) the kit isn't designed to accommodate the old seat and b) I don't know if I'll be pillioning haha though it is nice to have a girl sit behind you.

Hmm white and gold writing you reckon? I have seen that gold on the new ZX10r but also have seen a few whites. Ah well get the fairings painted first I think. Hmm back to study =(

[Twigs]

What you should do is use the white paint on something that'll get it similar to your bike, then find the different colours you have in mind and put them on the white to see....From there you might be able to go "Yay or Nay" Just an Idea.... So your not sticking different coloured stickers on the bike itself? (or a cheaper Idea, print the colours in text on white paper )
Loving the new seat- looks allot better.

[Frogger]

Frogger - yeah I think the headlights are a bit odd too, being so rounded compared to the rest of the bike.

yeah i agree when i had a zxr250 i was thinking of just getting the tank cover and tail as i liked the front end but wasnt sure how it would look.

[kessen]

twigs - the bike's going to be matte black not white. The white on there now is the primer it came with, which by the way, would you know what sort of primer that is just by looking at it? I think I shall go with that print a sample idea haha that's a pretty good idea thanks.

Frogger - sorry I meant the mirrors are a bit odd. I quite like the front, only thing is it does sit a tad low...almost droopy like. The headlights were a nightmare to fit and I didn't protect them very well when I was trial fitting it so now I've got these light scratches on them. I'm hoping an acrylic plastic polish will help?

Weather is beautiful today might be able to take her on her first test run =D

[falcon]

Mate, that looks ace. I vote go with white for the fairings, it looks great with the black everything else. Be different, there's too many black bikes out there.

[kessen]

Aw the original design was with white fairings but my mate bought a CBR600RR and always wanted a white bike so yeah his is now a completely white and sexy RR. Since we all go riding together couldn't have too many white bikes so I thought I'd mix it up a bit yin yang style.

Surely there aren't too many all matte black bikes like this one?

[falcon]

Dang, your mate sucks haha. Nah, whatever you do to it, this bike is going to be pretty unique I think.

How about Ducati red?

[kessen]

OOoo I did think of Ducati red today actually. Great minds right? haha but I just think maybe Ducati red should stay where it's named...Ducati...

sorta like the people who painted their MR2s 'Ferrari Red' after they put them F40 kits on them....I don't really wanna do that.

Just took it for a go down the street. Am a bit worried about the engine now =\ is making noises that it didn't before I started the tear down. I hope to hell age and being uncared for hasn't caught up with it...=(

[kessen]

Haha turns out it was all in my head.

Came inside sat down and tried to study but ended up back outside. Anyway I decided to test the fluid 'leaking' from the exhuast - collected it in a container and 10mins later noticed a black sediment on the bottom and water on the top. Looked up under the muffler and noticed there is a small drainage hole next to the bolt. All makes sense now..that exhaust has been sitting for a while so condensation and the build up of carbon inside just dripped out. YAY no problems there.

Was worried a head gasket or something but checked the oil and it was all clear. There aren't any signs of compression loss either so YAY (2)

Was noticing a lot of fumes. Checked for leaks and all, did find a small dribble from radiator hose so just clamped that tighter and stopped that. Then realised that the engine's been repainted with engine enamel...(duh)...so just baking in process =) Fumes have by and large stopped. YAY (3)

Soooo took it for a ride all the way around the block and yeah found a straight opened up the revs in 2nd and wow it was so smooth and just everything was yeah...can't wait to put it all back together and take it for a proper ride and then paint it!

Brakes need to be bled again but so far so good =)

[Frogger]

if u were to go white i reckon white rims to match would look so good. but i do like the ease of black bikes for cleaning reasons.