ZZR250 dirt tourer build.

Discussion in 'Some Assembly Required' started by tHEtREV, Mar 9, 2010.

  1. Whereabouts

    Whereabouts Been here awhile

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    :ear
    #21
  2. Belgian Waffles

    Belgian Waffles Been here awhile

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    :lurk
    #22
  3. dakdakdave

    dakdakdave an older,wiser noob!

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    Ttrev is resting....check out the aussie forums for the easter ride to waarnerring:1drinkhe did 3300kms on this in 4 days!! and that was just to find a dunny!! local legend .
    #23
  4. Jimmy the Heater

    Jimmy the Heater Dirt Farmer

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    I have a US Ninja 250 sitting in the garage....your project is looking mighty tempting! Tagged for the result.
    #24
  5. tHEtREV

    tHEtREV Encouragement award recipient. tEAM iDIOT.

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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.
    #25
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  6. tHEtREV

    tHEtREV Encouragement award recipient. tEAM iDIOT.

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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...
    [​IMG]

    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.
    [​IMG]

    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...

    [​IMG]

    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...
    [​IMG]

    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...
    [​IMG]

    [​IMG]


    [​IMG]

    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...
    #26
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  7. Jimmy the Heater

    Jimmy the Heater Dirt Farmer

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    Thanks for updating this....looks good! Waiting patiently for the RR:ear
    #27
  8. Neonasty

    Neonasty Been here awhile

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    Waiting for the reply mate.

    Good work on the quick build. Have a fun trip!
    #28
  9. Pezz_gs

    Pezz_gs Cant ride for crap

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    tREV

    Where is the ride report :deal
    #29
  10. atgreg

    atgreg Africatwinarama

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    hows the zzr going Trev ???
    #30
  11. 1WD

    1WD The Converted

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    Jan 26, 2007
    Oddometer:
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    Location:
    Adelaide, South Australia
    I was thinking about the Scrapheap ride today. Where would I find a bike for under a $1000... and I thought to myself, these guys must have old shitheaps in their sheds. And, I forgot that I aquired an unwanted ZZR250 from a friend a while ago... So I went hunting, and it's lead me here...
    Guess I'd better get it registered, and find me a dirtbike front end that will fit...

    Hey Trev... Can I pick ya brain for a bit....
    #31