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Old 03-20-2010, 10:28 PM   #16
Pezz_gs
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I was thinking the XR250 with the XL175 might be just the jigger for her

As those ZZR250KLXR's can be a bit of a handful for the beginners
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Old 03-21-2010, 03:17 AM   #17
tHEtREV OP
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I'm just finishing off the fiddly stuff so I can ride it and find out what I need to change.

Firstly I thought I'd give the rear plastics a hit of paint a bit closer to the tank colour.


Well the colour of the cap on the spray tins was a lot closer...

I had been playing around with a Staintune exhaust I had sitting around.

It fits OK, but pipe diameter is a big problem, and it sounds like a BMW, or a VW at idle...

I have one with a slightly smaller pipe in much better condition sitting at my parents place, so I might go out and grab it, it's also quieter than that old dinted one.

Last week I had fun messing around with lights, but I am really hating every screen I try to make for it.

This is whats on there now...


But I think I will end up running it without one, or a small one...
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Old 03-22-2010, 04:52 AM   #18
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I had some time up my sleeve today so I went down just to have a look at the thing.

I sometimes just go and sit on my projects and think where I want to go with them.

As I sat on it and went to turn the handle bars I heard this god awful scrapping noise.

I knew the gap between the mud guard and the head light was close, but after I put a bolt at the bottom of the head light shell to hold the rim in place it ran out of clearance.



And because I had nothing better to do I thought I may as well fix it.

So I got some old aluminium tubbing I had laying around and put for marks on it at 2cm intervals.



A few cuts later and I had four spacers.



Add some longer bolts and the problem was fixed.


While I was at it I went around the bike and tightened up any lose bolts and thought I may as well take it for a ride out to my parents house (40K away) to see what I have to change.

Unfortunately it pissed down rain as soon as I left town so I didn't hit any dirt roads, but except for a slight weave it felt good on the highway.

After about half an hour of trying things on it (the Staintune wouldn't fit...) and finally fitting a kick stand spring (I used a KLX kick stand for the extra length, but couldn't find a spring ), I headed home.

The rain had eased up so I took a very quick excursion of road.











On the way home I stopped at my local bike wrecker to grab a front tyre to see if that helps the handling at all.

The one I was using was a "not for highway use" old and hard bit of rubber.

I picked up a brand new road legal knobby for $65...



And while I was there having a look around I picked up a almost new death wing rear for $65 aswell...



So they were fitted tonight, I found the steering head bearings were a bit lose, and I lost a nut from the rear linkage, so between that, I hope I have solved the slight weaving problem...
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Old 03-22-2010, 12:09 PM   #19
Northwoods Yeti
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Old 03-23-2010, 06:22 PM   #20
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Quote:
Originally Posted by Northwoods Yeti

Me too !!!
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Old 04-11-2010, 07:42 AM   #21
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'89 Transalp . . . but I'm still working up the nerve to talk to her
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Old 04-13-2010, 01:18 PM   #22
Belgian Waffles
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Old 04-14-2010, 04:52 AM   #23
dakdakdave
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Ttrev is resting....check out the aussie forums for the easter ride to waarnerringhe did 3300kms on this in 4 days!! and that was just to find a dunny!! local legend .
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Old 04-16-2010, 08:54 PM   #24
Jimmy the Heater
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I have a US Ninja 250 sitting in the garage....your project is looking mighty tempting! Tagged for the result.
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Old 04-17-2010, 02:25 AM   #25
tHEtREV OP
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Argh, forgot about this thread.

I'm in the middle of the ride report, and I'm about to head out for the night.

I'll finish get the rest of the pics and my thoughts on it tomorrow.

Sorry for the delay.
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Old 04-21-2010, 04:26 AM   #26
tHEtREV OP
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I eventually ran out of time to complete the project, but just to get you up to date on what I did get done...

The rear suspension linkage...

The KLX dog bones have bigger bolt holes through them than the original ZZR items (KLX 15mm, ZZR 12mm).

I didn't think anything of it until I went to change the rear tyre and found how much play there was in the rear wheel (up and down).

So while I was at a hardware store I went searching the isles for suitable bushes.

I ended up buying a dyna bolt with a 16mm outer collar thingy...


Thats it in front of the vice.

I took the collar thingy off, put it in the vice and ran the hacksaw through the split in it to get it to close tighter.


Then I cut them into 10 mm lengths (I don't know if they were 10mm long, it was a long time ago)

Then I grabbed my favourite tool and belted the crap out of them, or gently taped them into the holes in the KLX dog bones...



The one on the left has the bushes hammered in, the one on the right is cringing in fear...

It ended up working nicely, I was very happy with it.

Bash plate.

I was a bit worried about protecting the vulnerably belly of the beast, but couldn't get one of the bash plates I had laying around to fit.

So I trimmed of a sheet of checker plate aluminium I had laying around into a rough rectangle and attached that to the bike with some hose clamps...


And then bolted a plastic box to each side for storage.

I was going to put some thick aluminium boxes on there but was a bit worried that they might puncture the cases in the event of an off, unlike the sacrificial plastic ones.

I also zip tied those two rusty mesh looking things to the front lower fairing mount for some protecting against flying rocks (there the stock rad guards from a KLR 250).

And then all that I had time for was to pack the thing and ride it half way across the country...







I should be finished the ride report by the weekend, so I'll wait until then to give my thoughts on how it went...

Sorry for doing such a rushed and crappy job on it, wish I had more time to do it, but thats life...
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"Far to the general now, and without great final hope of victory, he has nothing to lose. And it must above all have rabies. For the moment, it dominates this special."
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Old 04-27-2010, 06:48 PM   #27
Jimmy the Heater
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Thanks for updating this....looks good! Waiting patiently for the RR
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Old 05-02-2010, 02:43 AM   #28
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Waiting for the reply mate.

Good work on the quick build. Have a fun trip!
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Old 05-14-2010, 08:39 PM   #29
Pezz_gs
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tREV

Where is the ride report
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XR460/4 - http://www.advrider.com/forums/showthread.php?t=497905


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Old 07-29-2011, 04:33 AM   #30
atgreg
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hows the zzr going Trev ???
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