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Project CB250RS Restoration/Rebuild

Discussion in 'Your 250cc Projects' started by TechHeadFred, May 16, 2014.

  1. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    2007 CBF250F, 2004 KLR650, 1992 FZR400, 2 x CB250RS (1980 and 1982),
    Eric the Half a Bike

    So I decided I wanted to restore a CB250 RS, as I grew up as a pillion passenger on one.

    I went looking on eBay and found a couple. This is the one I won:

    [​IMG][​IMG]

    I was originally hoping to get it shipped from Melbourne but the cost was ridiculous. So much so that I borrowed a car with a towball, hooked up my trailer and went and got it myself.

    I decided that until it looks like a bike again, it shall be known as “Eric the half a bike” – if you get that reference you are either older than me or a hardcore Monty Python fan.

    While the motor seems to turn over from the kick-start and the gears seem to change smoothly, A couple of obvious problems were found immediately.

    The more observant of you may have notice that the right exhaust pipe is missing in the photos above, as well as a few key body parts, instruments and most of the electrical system!

    Other than this, I noticed the following;

    The speedo cable is missing its sleeve and the brake hose is not attached:

    [​IMG]

    The throttle cable sleeves are stretched as well:

    [​IMG]

    It also looks like someone has chopped off the back of the frame at some stage:

    [​IMG][​IMG][​IMG]

    Some bright spark has cut off the plug for the tail light:

    [​IMG]

    The rear brake assembly is missing a few parts:

    [​IMG]

    The next step is adding the parts I’ve already bought to Eric and figuring out what’s still missing:

    [​IMG]

    Fortunately, I have one of these and a brain:

    [​IMG]

    So, onto the basics!

    (Copied from my blog post of the same name)
     
  2. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    First work on Eric

    While taking the photos for the last post, the postman arrived with 2 parcels, so I decided to get started on a few basic things that needed attention.

    Speedo cable

    Before I ordered a replacement, the speedo cable looked like this:

    [​IMG]

    While the cable itself is in good condition, it’s missing the sleeve.

    Fortunately the replacement arrived today.

    Here they are side by side for comparison:

    [​IMG]

    Replacement was particularly easy, as there was a single screw holding it on to the front wheel.

    [​IMG]

    Cable run up to the handlebars with the tacho cable:

    [​IMG]

    Front Brakes

    Next, I attached the front brake hose. Unfortunately the master brake cylinder arrived with no front mounting bracket (add to the list of parts to order):

    [​IMG]

    Mirrors and Instruments

    I attached the cables to the speedo and tacho, added a mirror to the brake cylinder and Eric is starting to actually look like a real bike again:

    [​IMG]

    At this point it started raining so I got a couple of shots from further back and packed everything up for the day. I forgot to get photos, but I also swapped the throttle cables over from the replacement throttle assembly.

    [​IMG] [​IMG]

    That’s it for Eric this weekend. Hopefully the bolt kit will arrive soon and I can start putting the back of the bike together soon!

    (copied from my blog post of the same name)
     
  3. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    Eric’s Bolt Kit

    Bolt kit has arrived!

    [​IMG]

    Unfortunately I misunderstood what the bolt kit was for – it’s replacements for all the engine and carburetor bolts. While these are nice quality hex key bolts, what I needed was the bolts to hold the frame (i.e. everything else) together!

    Hmmm, will have to have a look into which ones can be repurposed…

    (Copied from my blog post of the same name)
     
  4. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    Vintage Tools and a Wrong Brake Lever

    So I had 2 parcels waiting for me when I got home this evening.

    The first one contained these wonderful genuine Honda tools, to start replacing Eric’s missing onboard toolkit:

    [​IMG]

    All good so far.

    The second one contained this after-market brake lever:

    [​IMG]

    On trying to fit it, I found that it’s not even close to fitting. I saw this on the label on the packet it came in:

    [​IMG]

    Looks like either they’ve sent me the wrong one or misrepresented the models it fits. Needless to say, I’ve contacted the seller. Hopefully it can be sorted!

    Update: Turns out the issue was that the master brake cylinder I managed to track down was from a 1980 model and takes a different brake lever to the 1982 model. Should be sorted once I return the wrong one, as the vendor will send me a replacement.

    (copied from my blog post of the same name)
     
  5. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Looking good so far Fred. :thumb_ups:
     
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  6. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    Thanks Murdo.
    Keen to see what's waiting for me at the post office on Saturday, I had 2 missed parcels this week!
     
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  7. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    A couple of parts for Eric were waiting for me tonight when I got home – an aftermarket ignition switch and a CDI box from a 1980′s CT110 that happens to be the exact same part number as the one from the CB250RS and a damn sight cheaper to buy!

    [​IMG]

    So of course I had to install the ignition switch as the dash looked a bit bare:

    [​IMG]
    Help, I’ve got no nose!

    [​IMG]
    Bolts are there, good to see.

    [​IMG]
    What can I tighten these with?

    [​IMG]
    Of course, I have just the right spanner from the vintage tools I ordered for him!
    Just like a bought one! Oh, wait…

    [​IMG]

    Now I just need the headlight mount and headlight to sit the dash on!

    [​IMG]

    Hopefully the headlight mount is one of the 3 parcels I'll be collecting from the post office tomorrow.

    Got a headlight (with cover), front mudguard and matching set of the remaining locks with keys on their way from Japan via Jauce (thanks to Ian B. for putting me on to them) so I might have to change his name soon at this rate!
     
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  8. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Hey Fred, CB250RS manual is now in the resources section , its not the best copy, but it should help you with your project.
     
  9. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    Already have one that sounds similar and a Haynes. Thanks though!

    Sent from my SM-G900I using Tapatalk
     
  10. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    Thanks to the admin who moved my threads to the right area - didn't realise there was a separate category for project bikes. :oops:
     
  11. Th3_Huntsman

    Th3_Huntsman Senior Member Premium Member Contributing Member

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    It is new mate!
     
  12. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    I noticed the thread announcing it after I posted the reply. More work done over the weekend, will update later tonight. :)
     
  13. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    Eric Gets Wired For Action and Bulks Up!

    This morning I decided it was time to get Eric’s air box, battery box and wiring loom in place.

    First up – off with the tank and check the components underneath!

    [​IMG]

    Looks like the regulator is there so I might not need my spare after all.
    Hang on, what’s that on the left?

    [​IMG]

    Can’t quite make it out yet…

    [​IMG]

    Ah! Looks like someone’s chopped off a wire instead of figuring out where it’s connected!
    Will have to check that later…

    [​IMG]

    On to the battery box! here it is – popped the CDI box in its holder while I was at it.

    .[​IMG] [​IMG]

    Here’s where it isn’t but should be:

    [​IMG]

    Fits well enough. I’ll have to find some screws for it though.

    [​IMG]

    Moving on to the air box. Here it is:

    [​IMG]

    And here’s where it should be but isn’t:

    [​IMG]

    It was a bit of a tight squeeze so I took the cover off to maneuver it in. Looks like I’ll need a new air filter element too!

    [​IMG]

    Only two screws for the cover, will need to look through my bolt kit or my box of random nuts, bolts and screws for something suitable later.

    [​IMG]

    So with the hard part done, I put the battery box back in.
    Found some Phillips head bolts in my box of random nuts, bolts and screws to attach it with (I ended up using these to hold the air box in too).

    [​IMG]

    On to the wiring loom!

    [​IMG]

    I figured I should find the other end of the chopped-off wire before attaching the wiring loom.

    [​IMG]

    Ahh. there it is! Attached behind the ignition coil.

    [​IMG]

    While I was there, I figured I’d check the spark plug.
    It was only finger-tight but looks serviceable enough for now.

    [​IMG] [​IMG]

    Back to that stray wire. Looks like I’ll need to get the ignition coil off to take it out.[​IMG]

    The double-ended bolt is attached behind the regulator, so that comes off too!

    [​IMG]

    The double-ended bolt with the washer and that pesky wire, then everything I had to take off to get to it!

    [​IMG] [​IMG]

    Since the regulator and its bracket were off I figured may as well save the bolts from it and put the spare on, as it came with the bracket. Also pictured is the wiring loom halfway through installation.

    [​IMG]

    After threading the cables through the headlight holder I found that it looks like the block for the ignition switch is missing – may need to find a suitable connector and check the wiring diagram later!

    [​IMG]

    I realised I needed the rear mudguard on to finish threading the wiring loom at this point. I used the bolts I’d saved earlier from the regulator bracket to screw it to the chopped-off section of frame.

    [​IMG]

    Since I’d already put the mudguard back on, I decided to put the seat and the rest of the panels on after I reattached the tank to see how he looked:

    [​IMG]

    And from the left side:

    [​IMG]

    And he’s starting to look like an actual bike instead of half of one!
    Sure, he still has no working lights, no brakes and no ignition and a missing muffler but he’s coming together nicely.

    I also bought a battery for him but will wait until the electrical system is closer to complete before I put in the acid and pre-charge it.

    (copied from my blog post of the same name)
     
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  14. Th3_Huntsman

    Th3_Huntsman Senior Member Premium Member Contributing Member

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    It resembles a bike again!
     
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  15. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    Yeah, might have to change its name from Eric the Half a Bike to something more permanent soon!
     
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  16. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Looking good there Fred. :thumb_ups:
     
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  17. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    Thanks Murdo!
     
  18. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    Eric Goes Strapless and Once More (With the Right Lever This Time)

    So I checked the mailbox today after sending the wrong lever back to the seller via Express Post on Saturday and found this waiting for me:

    [​IMG]

    Not one to make the same mistake twice, I figured I’d have a look at where it needed to go and check the retaining bolt before opening the plastic packet this time! [​IMG]

    Looks about right – let’s try them side-by-side.

    [​IMG]

    Sweet, time to fit it!

    [​IMG]

    Now I just need the front bracket for the master brake cylinder and I can take that wire off and actually use the brake!

    [​IMG]

    Speaking of things to take off, I have a replacement fuel tank strap on order with some other matching locks, so this broken one needed to come off.

    [​IMG]

    Turns out the lock is more for looks than anything else, as it was surprisingly easy to pop open with no obvious damage – so much so that I left how I did it off my blog. (Message me if you can't figure it out and have a similar issue to resolve!)

    [​IMG]

    Unscrew the mounting screws and it’s removed!

    [​IMG]

    A quick look in the tank shows a few rust spots but pretty good condition for a 32-year-old tank that’s been empty for several years:

    [​IMG] [​IMG]

    The underside of the cap could do with a de-scale though!

    [​IMG]

    The cap goes back on to keep the rust out…

    [​IMG]

    And finally a shot from the riding angle!

    [​IMG]

    (copied with a few minor edits from my blog post of the same name)
     
  19. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    In Which Nix Falls Repeatedly

    Yesterday was a busy day! Not many photos though.I found and bought many nuts & bolts a couple of suitable clips.

    Worked on Nix for a bit, then moved on to Eric.

    Screwed the seat cowl onto Eric’s seat

    [​IMG] [​IMG]

    Attached the side rails to the top of the rear shocks with M10 1.25 pitch nuts

    [​IMG] [​IMG]

    Bolted the seat on, after discovering that the engine bolts were either too long or too short to attach the side rails properly:

    [​IMG] [​IMG]

    Full bike shots from the left

    [​IMG]

    and from the right

    [​IMG]

    I decided I wanted to try the bikes side-on in the gazebo.

    [​IMG] [​IMG]

    Had some misadventures with Nix, then packed her up in the trailer and chocked it with bricks before putting Eric on his centre stand behind the trailer, giving up for the night and going for a cider!

    [​IMG]

    (copied with a few edits from my blog post of the same name)
     
  20. TechHeadFred

    TechHeadFred Well-Known Member Premium Member Contributing Member

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    Tidying Up Eric’s Tail End

    More parts arrived for Eric today.
    They’d already been partially disassembled to be packed for shipping, which saved me a fair bit of time.

    To prevent losing dropped parts in the grass, I flattened half the box the gazebo came in and parked Eric on it while working.

    [​IMG]

    The rear brake assembly was the first concern, as it was hanging a bit loose.

    [​IMG]

    A few parts from the brake assembly that arrived today, and voila!

    [​IMG]

    Next up was the tail light, which meant removing the seat and seat cowl as they are now screwed firmly together.

    Pulled out the temporary bolts holding the side rails, loosened the nuts on the rear shocks and flipped the side rails forward

    [​IMG]

    Unscrewed the seat mounting bolts and off came the seat.
    Unfortunately the back of the frame did too as I haven’t got it welded back on yet!

    [​IMG]

    Here you can see the chopped wires for the old tail light

    [​IMG]

    I lost a washer into the bottom of the rear mudguard and was VERY glad to have a telescopic magnet to retrieve it with!

    [​IMG]

    The tail light removed and its replacement for comparison:

    [​IMG]

    Bolted it back in and connected the matching wires.

    [​IMG] [​IMG]

    Slotted the rear of the frame back in

    [​IMG]

    Flipped the side rails back and bolted the seat on again and I’m done for the night!

    [​IMG]

    The rear brake doesn’t seem to have much effect so I’m probably looking at a new set of brake pads further down the track. That’s a problem for another day at this stage though!

    (copied from my blog post of the same name)
     

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