Shrinking a 300 to a 250

Show us that box of bits in your shed!
mellorp
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Re: Shrinking a 300 to a 250

Post by mellorp » Mon May 07, 2018 8:47 pm

A bit more progress

New crank in the cases. some lovely 3 bond and it's all torqued up nicely. Balance shaft with the most ridiculous alignment marks is in. Gearbox slotted in and all the gears select. Stator and flywheel on and some lovely new carb rubbers. Extra clips and washers back on ready for the clutch. The water pipe O rings had a liberal application of silicon spray to help them seat properly.

Impressed with the ease it goes together, although I do lay everything out as it comes apart so I just reverse what I did to put it back together. That way you don't actually have to remember what to do next as it's all laid out in front of you :-)

I had the engine mount welded last week so the next job is bolting the new top end on the engine and flirting it back in frame

https://www.flickr.com/photos/156864217 ... 2182914232

mellorp
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Re: Shrinking a 300 to a 250

Post by mellorp » Tue May 29, 2018 7:44 am

Spent a bit of spare time bolting the newly powder coated swing arm in. Looks good. Then spent a frustrating hour putting the BDK F3 valves and connecting rods together. 1st fix of adjusting the arms loosely and all working fine. New carb rubbers and gaskets and new pistons installed with a healthy douse of 2T oil all over the crank, small ends and rings. Barrels on finger tight before I'm ready to torque the head on and do the final kips adjustments.

As an aside I did buy an extra set of F3 valves and these will be sold with the 300 kit.

I should get the engine back in the frame this week. Once the clutch, electrics carbs (cleaned of course) are bolted on along with the brand new Venhill supplied cables, it will be ready for it's first splash of go juice. I'm getting ahead of myself here

So a quick recap. Powder coated wheels and many brackets including the swing arm (to me low priority). A pretty much brand new engine, new crank, ceramic plated barrels,wiseco piston kits, BDK KIPS valves (with 2 x std and 2 x F3) and arms, Fully refurbished brakes and new SBS pads with braided lines. And a new 5A battery. The larger capacity battery from the VJ23 fits in the battery box.

More pics to follow

mellorp
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Re: Shrinking a 300 to a 250

Post by mellorp » Mon Jul 09, 2018 7:19 pm

Another bit of progress. The KIPS valves are in and the motor is back in the frame. I realised, either a bit late or just in time depending on your PMA. The engine previously being a 300 was jetted differently from std. A quick call to NRP Manchester and some std stuff is on the way. Also found out no thermostat fitted in the 300 head. Is there a cheaper alternative available ?

KIPS valves working beautifully https://www.flickr.com/photos/156864217 ... 182914232/ Hopefully once connected to the servo the operation is as good :-)

mellorp
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Re: Shrinking a 300 to a 250

Post by mellorp » Thu Jul 12, 2018 6:43 pm

The clutch "star" had one weak arm. As I was tightening it I though it was a bit soft and sure enough twang it snapped. A replacement was quickly sourced and the clutch is in. Gearbox double checked and it runs up and down the gears OK. Carbs cleaned and adjusted as is the oil pump. New(throttle and kips) cables from Venhils are lovely. New fuel and overflow pipes (wemoto) mean everything rubber associated with the fuel delivery is brand new.
New thermostat and sensor ordered from Cradly. No point in doing all this then bodging it trying to rush at the end
I used genuine head, base and carb gaskets, but picked up a pattern gasket set for everything else. Even came with water pipe o rings.
Popped a battery on and everything that I can see needs to work is working, which is good
Fitted the zeeltronic today and set up the KIPS valves using my laptop. I'll probably download the settings from my other, well sorted, KR1s and program the 2 bikes the same. Should give a pretty good starting point. Of course I will have to recalibrate the KIPS valves and tweak it as no doubt there are minor differences

Some time soon I should be ready to fire it up using an auxiliary tank after a once over checking everything is torqued up properly. It might be ready to ride just as the sunny weather ends !!!

mellorp
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Re: Shrinking a 300 to a 250

Post by mellorp » Thu Jul 12, 2018 6:58 pm

What this means is I have surplus to requirements of
A 300 kit of crank, piston kit x 2, 300cc barrels and head with temp sensor (already reserved)
Swing arm
std Airbox
Set 4 kips valves, two original std (used) two F3 (brand new)
Set of 4 original kips wheels
Set of 3 original kips actuating arms
Clutch baskets clips springs and all plates. Missing parts are the "star" which has one arm broken off and the funny washer that sits between in the inner and outer baskets, the one that slides over the splines
Front and rear wheels
Fuse box
Side stand

Plus what ever else seems to have been duplicated. Once it's all bolted back together I'll make a definitive list and pop it in the for sale section

mellorp
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Re: Shrinking a 300 to a 250

Post by mellorp » Mon Jul 16, 2018 6:56 pm

I downloaded the map from the other KR1s and re set the KIPS valves then bolted on a few more bits, air box, pipes, added some Tyga end cans with a bit of drilling on the std pipes along with the proper exhaust support bracket. Rear pegs with new springs and clips. Work nicely. Also put new return springs in the front pegs. I realised the chain slider wasn't on so popped that on along with the chain and sprockets. A check that all things had been tightened before popping the fuel tank on. Yes I know it's in the house but it fired 1st kick but I quickly hit the kill switch !!!

Last few (never ending) things to add before it gets rolled out for a spin round the block, but that will be next week as I need to do other stuff

Latest pics on the Flikr album
https://www.flickr.com/photos/156864217 ... 182914232/
https://www.flickr.com/photos/156864217 ... 182914232/

mellorp
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Re: Shrinking a 300 to a 250

Post by mellorp » Sat Jul 21, 2018 10:15 am

Anyone interested in the 300 kit send me your email and I’ll send you some pictures

mellorp
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Re: Shrinking a 300 to a 250

Post by mellorp » Sun Jul 22, 2018 12:20 pm

Or PM my your mobile number if you use Whatsapp

mellorp
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Re: Shrinking a 300 to a 250

Post by mellorp » Mon Jul 23, 2018 12:22 pm

300 kit and KIPS valves sold

mellorp
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Re: Shrinking a 300 to a 250

Post by mellorp » Sat Aug 04, 2018 4:55 pm

Nearly there after a mad few weeks of not being able to work on any of my bikes :-(

New thermostat and temp sensor fitted, bolted on lots of other things and checked everything was torqued up properly. I think it's ready for a ride round the block. I'm looking forward to Sunday morning and a fight to get it out of the front door !!!!

Image002 by Philip Mellor, on Flickr

mellorp
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Re: Shrinking a 300 to a 250

Post by mellorp » Mon Aug 06, 2018 9:27 pm

So out in the sunshine and 3 heat cycles it's ready to go. No leaks, no misfires, no problems

A few tweaks on the tickover screws was required, and I want it to pick up a bit cleaner from tickover. Also need to check the throttle tube as it's sticking ever so slightly. All in all pretty minor stuff considering it arrived in boxes and it's the 1st time I've put a KR1s motor together.

Image001 by Philip Mellor, on Flickr

mellorp
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Re: Shrinking a 300 to a 250

Post by mellorp » Mon Aug 06, 2018 10:33 pm

For my benefit here's the full list of what's been done

As it arrived
Massive box of nuts and bolts all refinished
Powder coated parts
- Wheels
- Swing arm
- Foot pegs and hangers
Every nut and bolt loose or in a bag
none runner
Missing bits of electrics
300 engine
cracked rear engine mount
brakes seized
1 rough looking and intimidating pile of neglected bike

New stuff

Engine carbs and ignition
2 x replate of 250cc barrels
2 x brand new Wiseco pistons kits
1 x fully refurbished crank and new seals
2 x BDK F3 KIPS valves
2 x BDK std valves
1 x BDK KIPS wheels, arms and seals
Venhil Cables
- 2 x KIPS
- 1 x throttle
Genuine Kawasaki
- head & base gaskets
- Carb gaskets
Three bond
Other gaskets are pattern
Carb rubbers
Thermostat temp sensor
Std reeds
Tyga end cans on std exhausts
Clutch (complete)
Zeeltronic PCDI-10VT (map from my other KR1s). Cycles KIPS valves on start up.
Carbs cleaned, new fuel lines and overflow pipes. New vacuum pipe to fuel tap
Piper Cross Air filter
Oil pump ceaned, new oil line from 2T tank to pump
New battery
cut down airbox (to fit alternative shock)
Pipercross (for life) filter
NGK used BR9ECM for heat cycles and initial runs
NGK B9ES for normal use
Carb kit from Cruzin Images 37 Pilot Jet, 135 MJ, std needle clip #4 (2nd leanest) #5 being the one at the top, air screw 1.25 turns out, Float heights 19mm from base of carb to high point of the float. Tickover 1200rpm

Chassis & bodywork
welded rear engine mount
Front & rear calipers refurbished with new seals and pistons
New brake and clutch levers (you can't trust old stuff, it might suddenly snap on you if someone's being propping the bike up against a wall with the weight against the levers)
SBS pads front and rear
Braided lines 2 piece (race) front and single rear line
Torque arm rose joints
New swing arm
Swing arm bushes and seals
Shock linkage seals
Chain slider
Paddock bobbins
Various nuts, bolts rubber grommets and clips
Chain and sprockets
Sprocket locating tab
Rear sprocket bolts
New screen
Dunlop Alpha 10 tyres
R6 rear shock
Original tank and fairing
Full rear mudguard
Original mirrors
Original chain guard

Fluids
Castrol Racing fully synthetic 2T oil
silkolene EP80 gear oil
magnetic gearbox drain plug
100% water for heat cycles
Ready to use antifreeze for normal use
Super unleaded at 40:1 for heat cycles
Super unleaded for normal use
DOT4 brake fluid

Reference data/suppliers

KR1 hard copy manual
KR1s hard copy supplementary manual
Cradley Heath parts list on line
CMS parts list on line
Fastline spares (clutch)
Venhill cables
Goodridge brake lines
Powerhouse/Brakemaster brake caliper services and pads
Cradley Heath genuine Kawasaki parts
BDK Wiseco piston kits
BDK KIPs parts and information
The Tuning Works Zeeltronic ignition PCDI-VT10-KR with plugs
Base settings for Zeeltronic ignition originated from The Tuning Works
The Tuning Works Poten Aptec Ceramic plating spec'd to individual pistons
The Tuning Works refurbished (BDK or Grampian not sure) crank
Courier work by Anyvan (my friend Neil)
Welding by Joseph Percival (Stockport)
MOT at College Motorcycles (Stockport)
Insurance BikeSure (Adrian Flux) multibike policy

Workshop

Everything assembled by me in my living room
Estimated effort around 100 hours, achieved a couple of hours at a time with maybe 3 dedicated full days
Costs, I've enjoyed doing it exactly as I wanted to do it, so who cares.

Rationale

Is it concourse, nope but it has a brand new engine and excellent suspension and brakes. You want to look at a KR1s go buy a picture. You want to enjoy riding one then concentrate on making it stop corner and go like Kawasaki intended :-)

Riding it
Initial break in 3 heat cycles
1st ride gentle run up the bypass. No traffic runnign the engine up to 7k
2nd ride run to the red line to get plug chops
3rd and susequent runs. WOT agin on the bypass to get the jetting right
Suspension, static sag set to my 13st preference, and ridden round the twisty "A" roads to gain feedback and adjust as ncessary
Last edited by mellorp on Sat Sep 01, 2018 11:10 am, edited 3 times in total.

Gerrit
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Re: Shrinking a 300 to a 250

Post by Gerrit » Tue Aug 07, 2018 9:54 am

"Costs, I've enjoyed doing it exactly as I wanted to do it, so who cares."

Translation: "Top Secret, She Who Must Be Obeyed must NEVER find out!" :lol:

NIce work, another one rescued from oblivion.
"Mine is a long and sad tale", said the mouse.
"Indeed it is", said Alice, looking at the mouse's tail.

mellorp
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Re: Shrinking a 300 to a 250

Post by mellorp » Tue Aug 07, 2018 3:45 pm

Gerrit wrote:
Tue Aug 07, 2018 9:54 am
"Costs, I've enjoyed doing it exactly as I wanted to do it, so who cares."

Translation: "Top Secret, She Who Must Be Obeyed must NEVER find out!" :lol:

NIce work, another one rescued from oblivion.
Translation - This is one of twenty two 2 Strokes that I own. Doing up a KR is peanuts compared to the RGV500s (I have 2) or the NSR's (I have 5).....

mellorp
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Posts: 330
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Re: Shrinking a 300 to a 250

Post by mellorp » Tue Aug 07, 2018 7:35 pm

Soldered up the wonky wiring on the llights and side stand switch. All the bodywork on a quick wipe down with an oily rag and that's it. Finished

Image016 by Philip Mellor, on Flickr

Image019 by Philip Mellor, on Flickr

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