ZZR250 service

[rooster89]

Hey guys i just stripped the fairings off my 99 zzr to service it and i have a few questions.

1. Is the oil filter at the bottom of the engine and is it cleanable or do you replace it. I haven't pulled it out yet cos im not sure if what im looking at is the oil filter.

2. My rear brake resevoir is empty does this mean i have to bleed the rear brake even though it functions fine?

3. To drain the coolant do i just take the hose off the bottom of the radiator and let it drain out of the radiator and engine or is there a better way?

4. There are 2 lines coming off the fuel tap. One is the main fuel line and has a filter but the other is smaller and goes to the other side of the carbies. What is this line and should it have a filter.

Thanks

[Cwidova]

hi,
i always replaced the oil filter when i serviced the old zzr but maybe you can get a reusable one? and yes it is on the bottom of the engine(the bolt and round plate near the drain plug)
if the resevoir is empy i would start looking for a reason why they generally dont go empty unless something is leaking.....i would also bleed new fluid through it is better to be safe than sorry!!
you can remove the bottom hose but there is apparently a plug on or under the water pump to drain it!!!it was shown in another thread but i cannot find it sorry
the second line that comes from the fuel switch to the carbies is a vacuum line to operate the diaphram in the switch and it doesn't need a filter but make sure that it is good condition, unblocked and connected casue if there are any problems with this line the fuel switch doesn't operate properly
hope this helps

[rooster89]

Thanks heaps cwidova. That helped heaps. The fuel filter that on there is a little cone shaped filter with one fitting on the top and one on the side, it's about the size of a quail egg haha is that a good enough filter?

I looked on the water pump but couldn't find a drain plug.

[Cwidova]

yeah that should be good enough as long as it looks clean and you can blow through it(they are directional usually so it might only flow through one way)there is also a mesh filter for the fuel pickups unside the tank but they dont usually block up!!!
as for the drain i am only going on what i have heard as i have only taken the bottom hos off and drained the coolant like that.....don't forget to take the filler cap off so that the coolant drains faster!!!!

[rooster89]

The other question i forgot to ask about is that there is a slight knocking noise when it runs in neutral but it goes away when i pull the clutch in. Is that just an adjustment problem?

[Six Addict]

that knocking noise is something i believe kawasaki's do ... checked out a ZX6R and it did it...

[Cwidova]

the knocking noise i have been told by a few people is the clutch basket chattering......it is a common thing in those engines and nothing to worry about (my old zzr250 that i sold to a friend has done 100k+ on the same basket with no issues whatsoever!!!)

[Lainie]

Hey buddy, I am located in Hampton Park if u need to bring your bike over for Tony to have a look at just buzz me. I also have the service manual for the GPZ on PC if u need that same motr etc and the ZZR.

Cheers Lainie

[rooster89]

Thanks lainie i'll let you know if i need any help. Hey cwidova when you drained your coolant by taking the bottom hose off the radiator did the stuff from the block and water pump drain out too?

[Shifty]

There's two things you need to do underneath... one is the main oil drain plug and the other is the actual filter itself.

Just replace the filter, they're about ten bucks.

Air filters are hideously expensive, instead I use generic filter foam for dirt bikes. Cost me about $15 and there is enough for three filters.

[rooster89]

Can i get the dirt bike filter foam from any motorbike shop? And do i have to soak it in an oil? cos the element in there at the moment has an oil on it.

[rooster89]

Well thanks for everyones help. It's finished with no dramas apart from one of the front brake resevoir screws is rounded so i can't drain get to the fluid haha. If anyone has any ideas how to get it out i would appreciate it.

[dave#3]

Well thanks for everyones help. It's finished with no dramas apart from one of the front brake resevoir screws is rounded so i can't drain get to the fluid haha. If anyone has any ideas how to get it out i would appreciate it.

Very carefully with an easyout. Whoever designed that reservoir with countersunk phillips head screws should be strung up by his nuts.

[rooster89]

Agreed!
Thanx i'll give it a go soon (when i muster the courage haha)

Where should the temp gauge sit. At idle it sits comfortabley with the thermo fan kicking in and out holding it steady. i can get pics if needed. I haven't been able to take it out for a ride. There just seems to be a lot of heat coming off the engine but im not sure if this is normal as im new to motorbikes.

[Cwidova]

sorry for leaving so late in reply.....there should be some that comes out of the waterpump/block but i don't remember how much....as for the temp if the needle sits ok when it is idling and the thermo kicks in and out, when you are riding it should run cooler as ithas more airflow!!!