ZZR 250, 600, 1100 & 1200
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Blown head gasket?

Sun Oct 09, 2011 5:45 pm

Hey guys

Iv been following these forums for awhile and am finally in a pickle and need advice. So the story so far. Last week I did a oil change and noticed I had oil sepage from the camshaft seal so I bought some silicone sealant pulled the cover off and put some sealant on there and patched it up. During this service I also cleaned and re-oiled my air filter and put some carby cleaning additive in my fuel. Bike ran well the next day on the way to work with the minor exeption of a short cluggyness in response from my engine kinda the same feeling u get when ur outta fuel and have to switch to reserve, anyway that only happened for a min and I thought nothing of it. The next day I had to travel to the city, no problem on the way however when I got there and was looking for parking I noticed my temp gauge was a lot higher then normal didn't get in the red tho and it cooled down when I had air goin through the radiator, parked it and it was fine on The way home. The next day too work it was fine but on the way is where the real issue started, I took off from a set of lights and the bike once again became unresponsive I was driving full throttle but compression was kicking in and out so didn't get much speed for full throttle even on the highway I was doin less then 100 with full throttle and it was a real struggle to get home. When I got home I started thinking what it could be, my first idea was a cylinder wasn't fireing so bought some plugs fitted them and tried it out, same problem :( next check coils for spark both spark fine. Next I noticed oil sepage in the same spot so cleaned all the sealant off refitted tried again, same problem next I removed the air filter and tried again same problem so now here I am thinking its a head gasket or its the fuel additive I added. Any suggestions on what the problem could be would be great also if any1 has a copy of the base ex-250 workshop manual that would help heaps the zzr suppliment just doesnt have enough information

Re: Blown head gasket?

Sun Oct 09, 2011 5:55 pm

Is the oil "creamy" ?

Re: Blown head gasket?

Sun Oct 09, 2011 6:02 pm

It is creamy white but when I took the cam cover off I had to take the coolant hose off and it did leak some coolant into the top section of the engine

Re: Blown head gasket?

Sun Oct 09, 2011 6:15 pm

Blown head gasket, probable .... :cry:

Re: Blown head gasket?

Sun Oct 09, 2011 6:20 pm

Drain some oil from the sump, or have a close look at the oil from the oil cap. Creamy in there?

Re: Blown head gasket?

Sun Oct 09, 2011 6:32 pm

Yea the oil on the cap is creamy can't check sump atm too dark now

Re: Blown head gasket?

Sun Oct 09, 2011 6:35 pm

I'm pretty sure it is head gasket after the overheating and it feels just like compression ill get a compression gauge 2moro and check it

Re: Blown head gasket?

Sun Oct 09, 2011 6:39 pm

Head gasket. Sorry dude.
When the head gasket goes, It leaks coolant/water into your oil.

Re: Blown head gasket?

Sun Oct 09, 2011 6:54 pm

its not too bad, gasket its self is only $45 problem is fitting it how hard of a job can it be? if its harder then getting the carbys out im screwed lol so any1 got the base manual?

Re: Blown head gasket?

Sun Oct 09, 2011 7:29 pm

*If* I remember correctly, the ZZR-250 uses the GPx250 manual with updates.

Re: Blown head gasket?

Sun Oct 09, 2011 8:31 pm

just another thought, to get me up and running till the weekend when i can replace the gasket is it safe to use those seal up products on motorbikes? I have had great success using it in my old 4x4 and i really need this thing fixed quick

Re: Blown head gasket?

Mon Oct 10, 2011 1:58 pm

from someone that has done a couple of zzr head gaskets i would strongly advise pulling the motor out

its only a couple of extra bolts and a couple of wires and the motor drops straight out

makes life a shitload easier to replace the gasket and reassemble

otherwise you are bent over for hours trying to make it all happen

also gives you a chance to clean everything well


re carbs , easier if you unbolt the subframe and let it drop back

Re: Blown head gasket?

Mon Oct 10, 2011 11:01 pm

Yea i will definitely pull the engine out to replace the gasket might even flush the carbs properly while im at it. does anyone have a copy of the gpx250 manual they can email me? im pretty stumped as to how to remove the engine and i dont want to do my usual thing and just start pulling things apart till i get what i need lol

Re: Blown head gasket?

Mon Oct 17, 2011 8:25 am

Ok so removed engine and replaced head gasket over the weekend, now it won't start :( starter motor turns but engine just won't kick in, one thing I'm thinking is a dry carby since I removed and drained it is there a way to manually feed fuel

Re: Blown head gasket?

Mon Oct 17, 2011 10:24 am

has your tank got a petcock with "pri" (prime) on it?
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