91 tzr250 sp - Chicagoland Sportbikes
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post #1 of 32 (permalink) Old 11-02-2010, 12:57 PM Thread Starter
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91 tzr250 sp

Finally i was able to put fund on my TZR. Its been 3 yrs just sitting in my garage. I have to skip 2 trackdays so i have money to buy parts

Here it goes.

When it was in one piece.


Unfortunately the crank blew up so the engine has to come out. The original one was a wet clutch.



I opted to change the engine with a SP(dry clutch) so i bought a used one from Japan.This was like 3 yrs ago









Upon inspection it had a seized lower cylinder and it due for a new crank.
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post #2 of 32 (permalink) Old 11-02-2010, 01:00 PM Thread Starter
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3 years had passed i decided to make an effort to build it one piece. Plus some parts are getting lost.

Bought a used crank(New one cost $1200) and got the cylinder replated at Millenium Technologies in Wisconsin ($200)
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post #3 of 32 (permalink) Old 11-02-2010, 01:02 PM Thread Starter
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The fun part.

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post #4 of 32 (permalink) Old 11-02-2010, 01:05 PM Thread Starter
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Almost there.


2 hrs later done.
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post #5 of 32 (permalink) Old 11-02-2010, 01:05 PM
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Nice!!! I like these kinds of projects.
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post #6 of 32 (permalink) Old 11-02-2010, 01:06 PM
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I can see why you may be missing some parts.... see above pictures....

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post #7 of 32 (permalink) Old 11-02-2010, 01:08 PM Thread Starter
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Since the old engine is different with the sp engine cylinder the exhaust flange wont fit.






Off to my friend machine shop to modify flange and make a spacer. Another $200
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post #8 of 32 (permalink) Old 11-02-2010, 01:11 PM Thread Starter
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Time to put the engine in.



3 hrs later, i got it in. Waiting for battery, air filter and cables for the powervalves.



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post #9 of 32 (permalink) Old 11-02-2010, 01:12 PM
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Cool as hell.

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post #10 of 32 (permalink) Old 11-02-2010, 01:13 PM Thread Starter
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I can see why you may be missing some parts.... see above pictures....
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post #11 of 32 (permalink) Old 11-02-2010, 01:20 PM
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Nice work.

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post #12 of 32 (permalink) Old 11-16-2010, 11:01 PM Thread Starter
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Got my battery and installed my air filter. Almost done just waiting for the power valves cable.





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post #13 of 32 (permalink) Old 11-16-2010, 11:06 PM Thread Starter
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Taken from my BB phone today

http://www.youtube.com/watch?v=QSHXIB3KORk
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post #14 of 32 (permalink) Old 11-17-2010, 12:03 AM
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very nice! sounds weird with the dry clutch lol

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post #15 of 32 (permalink) Old 11-17-2010, 12:17 AM
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Just saw the video, is your throttle mounted in reverse or is there just a delay on the sound in the video?

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post #16 of 32 (permalink) Old 11-17-2010, 08:12 AM
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wow, that cable gauge on the battery sure is small.

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post #17 of 32 (permalink) Old 11-17-2010, 09:45 AM
 
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sweet bike. want to trade for a sv1000, when you're done of course?
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post #18 of 32 (permalink) Old 11-17-2010, 08:59 PM
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Nice can't wait to see it.

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post #19 of 32 (permalink) Old 11-17-2010, 09:23 PM
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Quote:
Originally Posted by SmartDrug View Post
Just saw the video, is your throttle mounted in reverse or is there just a delay on the sound in the video?

I'm thinking that he needs to get a better cam... and clean up his garage...

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post #20 of 32 (permalink) Old 11-17-2010, 10:27 PM
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I'm thinking that he needs to get a better cam... and clean up his garage...
wat?


Looks like a sound delay from the sequence showing the tach.



Kickass project!

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post #21 of 32 (permalink) Old 11-18-2010, 06:12 AM
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wat?


Looks like a sound delay from the sequence showing the tach.



Kickass project!
cam=camcorder

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post #22 of 32 (permalink) Old 12-01-2010, 10:51 AM Thread Starter
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Nope. Just the camera angle and crappy blackberry cam.

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Just saw the video, is your throttle mounted in reverse or is there just a delay on the sound in the video?
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post #23 of 32 (permalink) Old 12-01-2010, 10:53 AM Thread Starter
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Yes i think its a 12 or 14 gauge. Its about right and this is bigger than the original wire.

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wow, that cable gauge on the battery sure is small.
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post #24 of 32 (permalink) Old 12-01-2010, 10:53 AM
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cool project!

Shitty Pass Racing #513
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post #25 of 32 (permalink) Old 12-01-2010, 10:55 AM Thread Starter
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Finally done putting it back together. Jetting will be done next year when the weather is warm. Still have to deal with the carbs overflowing.

My $80 cents coolant reservoir


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post #26 of 32 (permalink) Old 12-01-2010, 10:56 AM Thread Starter
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Jon just for you, i cleaned up.





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post #27 of 32 (permalink) Old 12-17-2010, 04:36 PM
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The coolant bottle needs to vent to atmosphere. Could cause the cooling system to cavitate/not circulate.
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post #28 of 32 (permalink) Old 12-17-2010, 05:01 PM
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Very nice. Now where is mine?
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post #29 of 32 (permalink) Old 12-18-2010, 11:16 AM Thread Starter
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Yes its still available. Both the steel and friction plates are all worn out so I plan to change it.

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Yamaha is still available, but are sold individually, not as the kit. They are not very expensive. The notched plate which has mounting rubbers is about double the price of the other friction plates. Its springs are very cheap so are well worth replacing at the same time. Its steel plates will usually be fine to re-use so long as they are not warped.
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post #30 of 32 (permalink) Old 12-18-2010, 11:24 AM Thread Starter
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Very nice. Now where is mine?
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