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Project Yamaha SRX 250 3WP

Discussion in 'Your 250cc Projects' started by Andych, Oct 9, 2016.

  1. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Any area's that were rubbed through to the next layer will need to be sealed off before repainting,
    best thing to use is a 2 part epoxy primer and let it cure for a few day's before rubbing back, if you rub through it it'll need another couple of heavy coat's then rub back again.
     
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  2. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    This was basically a trial run to make sure I was happy with the colours.. hence the Aerosol cans.
    I have their 2 pak primer and the paint I have is also 2 pak so hopefully it will all be fine..
    It served the purpose though.. I do like the colours :)
     
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  3. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Finally got to do a bit on the SRX today... before it became arctic down here (currently 8.5 feels like 2.3 and that is warmer than 2 hrs ago).
    Made up a new Starter cable and earth cable... both heavier cable than standard. Soldered ends as I dont have large enough Crimping Pliers.
    Mostly have the new (old) harness in the correct position now.
    I still need to put new seals into the FZR600 forks and paint the lowers.. as well as a multitude of smaller stuff but each time I am a little closer.
     
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  4. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Got back into the SRX today... front forks off and stripped. I grabbed an old FZR250 fork inner from @GreyImport last week while in the Arctic North, just to see if the inners would swap over... unfortunately not. There are a number of differences mostly in sizing.
    The big difference is in the springs. The 600 has a small spring (similar to the rebound spring) sitting on top of the progressive main spring. The damper rod is a bit bigger and the holes in the Damper rod or smaller... I will post some pics a bit later.
    Overall the inner on the FZR600 is 50mm longer than the 250.
    the 600 forks were in good condition, there was plenty of oil in there and it didnt smell horrific, which is a bonus. The seals were not too bad and I could probably have gotten away with just painting the lowers... but, at least now there will be brand new seals, dust covers to match the paint..
     
    Last edited: Aug 30, 2020
  5. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Pics of the Forks
    Parts as they come out... Spacer, heavy short spring and seat, main progressive spring, Damper rod (with rebound spring)
    UNADJUSTEDNONRAW_thumb_13fa.jpg
    UNADJUSTEDNONRAW_thumb_13fb.jpg
    UNADJUSTEDNONRAW_thumb_13fc.jpg
    UNADJUSTEDNONRAW_thumb_13fd.jpg

    This shows the difference between the Damper rod and rebound spring.. . FZR250 is on the right
    UNADJUSTEDNONRAW_thumb_13fe.jpg

    And I managed to get 3 coats of Gunmetal grey metallic onto the lowers... 2K clear maybe next weekend... maybe..
    UNADJUSTEDNONRAW_thumb_13f6.jpg
    UNADJUSTEDNONRAW_thumb_13f7.jpg
    UNADJUSTEDNONRAW_thumb_13f8.jpg
    UNADJUSTEDNONRAW_thumb_13f9.jpg
     
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  6. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Still waiting on having enough stuff to clear coat before laying some 2K clear onto the fork lowers... maybe next weekend.
    I have been checking out as much info as I can on the FZR600 forks and I think I will be deleting the small heavy spring that is at the top... It isnt in any of the parts lists and even a fat fella like me cant put enough pressure on the springs to get the top cap done up with it in there... Besides, the SRX is substantially lighter than an FZR600 and I can use the adjustable caps I have as they are the same thread... so I can add some extra preset if needed.
    All parts carefully packed away awaiting the lowers to be clear coated.
     
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  7. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    So... finally back to the poor unloved SRX...
    Front forks have been clear coated and re-assembled... discs have been painted (did I say how much I hated masking up floating discs for painting) and the front end reassembled.
    I still need to sort out new brake hoses front and rear but plenty of time over the next few weeks (3 weeks leave will go quickly though).
    UNADJUSTEDNONRAW_thumb_1bbc.jpg
    UNADJUSTEDNONRAW_thumb_1bbd.jpg
     
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  8. 2valve

    2valve Well-Known Member

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    That's looking very nice there buddy , you've done very well.
    Those front rotor's / caliper's are bloody huge !. That is a one pinky finger brake set up if i've ever seen one. I wasn't game enough to try a emergency stop on my stock set up , but your set up is in a different league.
     
  9. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Umm. Yep, slight overkill but hey, the only differences to the donor are Horsepower and some weight


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  10. 2valve

    2valve Well-Known Member

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    I meant no criticism , it actually completes the front of the bike , being a double side front end. I don't really like the look of the O.E single disc front end , it just looks wrong. Hence liking what you have done.
     
  11. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    All good mate, I must admit I prefer the twin disc setup as well. I just went a little overboard


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  12. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    @2valve asked me a while ago how I was going to match up my rear brake pedal with the new chromed gear lever.
    I decided last night to clean up the brake pedal with a wire brush on a drill and a light abraisive brush... then dunk it into the palting bath to see how it turned out... well a little more complicated than that but you get the drift.

    Well, I am pretty pleased with it... not as smooth as chrome but a far cry from the dull cast steel pedal it was originally.
    IMG_6162.jpeg IMG_6163.jpeg
     
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  13. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    After much pondering and procrastinating (I am good at both apparently) I need to do something with the little SRX350 (nee 250).
    The modification and Club rego laws down here in Mexico are pretty strict. The bike would need to be insepcted (indepently) to ensure it is pretty much as per factory (yeah right) for a Pink Slip (or is it a Blue Slip... meh) and then it can be safety inspected buy the relevant club for Historic / Club rego.
    After discussing my plans with a person that does the Pink Slip checks I wont be using the FZR forks or Triple Tree. It changes the bike too much and the cost of having an Engineering Cert done is out of the question.
    So I have some bits coming from Japan and forks from Qld to put it back to mostly normal SRX250 front end.... but with the 3WP top bridge to make it easier for headlight, gauges etc.
    I will need to sort out a brake setup but that should be ok. It will be a single disc still using the FZR250 3LN rim as it is the same specs as a 3WP.
    Once I have all that sorted I will most likely put her up for sale... So expressions of interest will be considered... just bear in mind the 350 engine, a rebuilt standard 250 engine (matching numbers to the frame) plus a lot of other SRX spares...
    Once I have a few things sorted out I will post some more...
     
  14. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    A bit more investigation has revealed so interesting info... the standard front disc on the SRX250 3WP is the same as a TZR125.
    This is 320mm diameter and the caliper is a single piston item.
    The mounting dimensions are the same for the FZR600 discs I have at the moment so the theory (at present) is to see how it all mates up using a single FZR600 floating disc and a single 4 pot caliper all mounted on the stock SRX250 front end.
    Anyone interested in a set of FZR250 3LN forks with new seals and inner tubes or a set of rebuilt FZR400 front forks...
    I need to pay for some of the bits I have ordered...lol
     
  15. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Message me about the FZR250 forks and how many pesos u require for me to take possesion :D
     
  16. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    After finishing off the new workbench toda, I was sorting through a few crates and happened on my FZR250 calipers... just to see what size they are I offered it up to the SRX250 fork and low and behold... same bolt spacing.
    Now how they sit relative to the disc for offset and diameter is yet to be determined.. I will wait till I have the upper and lower bridge in my hands from Japan... then I can mount it all up on the bikewith the front wheel and see how it all fits together.. who knows... it might even work lol
     
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  17. 2valve

    2valve Well-Known Member

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    Hi Andy
    Speaking of front brakes , found this SRX for sale. I asked the owner what caliper that was fitted , but didn't know. Is it what you have ?.
    Brakes.jpg
     
  18. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Yep, although my front wheel is an FZR250 so will have a different disc but it all looks a lot more do-able ( and easier) than what I have on it right now.
    Depending on how it all fits I might not have to even make an adapter, but I couldn’t be that lucky lol.


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  19. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    What size discs are you running now 282mm or 298mm?

    I've done a few measurements, so this isn't completely comprehensive, but it seems that a caliper/disc/fork leg combo is designed in harmony for a particular disc diameter.

    I've had a look at 1989 TZ250 USD forks, owner wanted to swap in axial monoblock calipers, hole spacing is correct @100mm, but the monoblock calipers came off of a bike with 298mm rotors - they bolt up fine, ~8mm the pad area is out off of the rotor outer circumference - so that is down to the actual calipers themselves.
    So the fork lowers seem to be consistent - caliper mounting lugs on the calipers themselves seem to vary depending on the rotor diameter.

    Notwithstanding that there are two mounting hole spacings 83mm on some models and 100mm on others.

    Additionally Yamaha disc offset from that period seems to be a consistent 10mm/10.5mm [measured from the back mounting face to the outside face of the disc].

    Also I've got a TZR250 3VX front wheel, it is 3", whereas the FZR250 is 2.75", however it differs in the hub width, 113mm for the TZR250, whereas the FZR250 is 103mm

    Fork spacing on the FZR250 is 185mm

    I'll go out on a limb and say the TZR250 is 195mm, because of that 10mm hub width difference.
    For example, on @maelstrom USD fork database the FZR600 3HE is 195mm
    https://www.litetek.co/Guide_USD_ForkDatabase.html

    It seems that Yamaha being sensible changed the hub width to accommodate different fork spacing because that leaves disc offset, fork lowers and calipers all consistent.

    NOW if you need to smuggle millimetres to get the correct disc spacing [increase], see the link below

    https://www.projection-components.c...nelli-brembo-6-bolt-various-widths-1326-p.asp

    IMO it would be a shame to see you sell that SRX after all of that work
     
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  20. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Interesting... I have existing FZR250 3LN discs (I will only use one with the SRX forks) and the discs on the bike at the moment are FZR600 which suit the swept area of the Gold Spot calipers.
    Once I get all my bits from Japan and can bring the rest of my SRX bikes over from the storage shed I can start to do some trial fit ups to see how they all fit and which is easiest.
    It will either be FZR250 disc and RHS FZR 250 caliper or FZR600 Disc, Gold spot caliper and an adapter plate similar to the pic below.
    The FZR250 and SRX mounts are 83mm where the Gold Spots are 100mm. It will be interesting to see how it all pans out.
    Either way it will have better front braking than the standard single piston slide caliper from the original SRX250.

    As for keeping it... jury is still deciding.

    As you can see... the rear piston doesnt fully cover the disc in this conversion... so not ideal.
    This is on an XS650 but the principle is the same...
    FazerCaliper100.jpeg
     
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