ZZR250 motor update

[Marty ZZR rider]

This is for the information of anyone contemplating giving their old ZZR250 a new life with a fresh engine. i just finished putting an engine from a 2006 model into a 1990 model ZZR250. It went straight in no mods, no bracket changes or anything. And better still I transplanted the engine complete from the carbies to the coils and did not need to modify any electrics. I used the new coils 2006, but left the rectifier and igniter on the 1990 model. The old header pipes coupled straight on to the 06 model as did the airbox to the new carbies.
I also transplanted the gauges (to show the true age of the motor) and the rear shock. The only difference on the gauges was that the tacho on the 2006 model redlined at 13000 rpm rather than the 14000 RPM on the 1990 model. I don't believe it makes a great difference but at least the tacho I have on the bike was the one designed for the engine.

So if you see a cheap engine in a wrecked late model ZZR250 yes they are all the same.

[Daisy]

Fits straight into a GPX too.

[MrWasabi]

show us some of your handy work!!!
might look for some wreck 2006 models... call metro spares on Monday

[Marty ZZR rider]

Here are some pics I took of the instrument upgrade:

Instruments_3.jpg (148.98 KiB) Viewed 5881 times

Dismantling the gauges was fiddly the needles are hard to remove but can be prysed off with two screwdrivers.

Instruments_1.jpg (124.24 KiB) Viewed 5881 times

I think the final result was worth the hour or so spent:

Instruments_2.jpg (149.2 KiB) Viewed 5875 times

[Marty ZZR rider]

Here are the pictures I took during the engine transplant.

2006 EX250 motor.jpg (21.64 KiB) Viewed 5857 times

Engine_change_2.jpg (122.98 KiB) Viewed 5855 times

Engine_change_3.jpg (170.91 KiB) Viewed 5854 times

Engine_change_3.jpg (170.91 KiB) Viewed 5854 times

Engine_change_5.jpg (156.75 KiB) Viewed 5854 times

[MrWasabi]

looks cool man. where did you pick up the engine from? and if you dont mind me asking, how much did you pay?

also were there any side costs to the project? like special tools you had to buy or unseen issues you ran into that could have been avoided up front?

[Marty ZZR rider]

The whole job required no special tools and was not that difficult. I worked on the bike while it was on the big stand. A good 1/4 metric socket set and a few 1/2 drive metric sockets (12,14,17 and 19) and a couple of screwdrivers did most of the work.
To diassemble:
I took off the tank and seat and then all the fairings. i then removed the radiator and then the exhoust in one piece. I then removed the gauges and rebuilt ours using the new internals. I removed the motor and then the airbox, I think it can only come out through the front after the motor is out. I then had easy access to the rear shock once the motor and airbox were out. I split the airbox while it was out and gave the inside a good clean, the old motor must have been pressurizing the crankcase and blowing a bit of oil into the box through the breather pipe.
To assemble:
I put the airbox back in.
Put the new motor in. just hanging on the two back bolts.
Installed the exhaust.
Installed the radiator and front bracket.
Lifted the engine slightly and tightened all the bolts I locked the nuts with loctite 242.
At this stage I plumbed the radiator and connected the airbox to the carbies.
I reconnected the clutch, all wiring, throttle and choke cables. I put the instruments back in place.
I put on the tank and put the battery back in and was able to start the engine. The rest was just replacing the fairings, seat etc.

I bought the motor on Ebay for $500 it had done only 5,600 kms. I was able to get some other parts from the same bike when I picked the motor up.

I paid $50 for the instruments but they were pretty trashed, I used only the internals.
The rear shock I paid $100.
I also bought the top triple clamp for $50 as our ignition switch has been ruined by someone trying to start it with a screwdriver.

So for $700 total it was a pretty good update.

[Marty ZZR rider]

The finished product is on the road and running

Phil on 250.jpg (216.33 KiB) Viewed 5764 times

It was a great day today for a ride:

ZZRs.jpg (170.28 KiB) Viewed 5763 times

[Magpain]

Well done! the ZZR250s seem like pretty easy bikes to work with. I shoulda just put one together out of wrecked ones insted of paying for a complete one.

Cool thread.

[Nanna10r]

Awesome thread Marty, that means all the gear will also bolt straight up to my GPZ250R. If you dont mind any idea what type & size carbies are on the 06 model & does the 06 Rear shock have more adjustment then just Preload ?.
Cheers Brett

[GuJohnno]

Excellent thread and great tech info.

Hey, don't suppose you have a radiator left over from it do you