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Project Honda CJ250 street scrambler

Discussion in 'Your 250cc Projects' started by Murdo, Feb 11, 2018.

  1. Murdo

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

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    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, XL250, CBR250, ZZR250 plus a few others.
    I bought this poor barstardised CJ250 a couple of years ago (maybe more) with another bike that I have since restored with the idea of because it had a rebuilt engine I would find another CJ with crap engine and swap to make a viable runner. Didn't happen so (as you would know if following my exploits that I like a challenge to keep the grey cells working) now have decided to rebuild the frame, running gear, etc, as a street scrambler. I luckily found a set of original Honda CL450 pipes at a sale (nobody knew what they were) and if I can fit them then it should look pretty good (these run up the left hand side of the bike with twin outlets). The frame has been 'butchered' (no other word to describe it) by the PO to make a "bobber" (Oh god save us from those with tools and no idea) and many bits 'hacked' off with an angle grinder (and not nicely either) and other bits of 'crap' welded on with a stick welder (and he was not welder, maybe he just hasn't found his place in life - and working on bikes is NOT it) to leave a bloody mess. It was just the engine in the frame and with an old XL250 carb and some bodgy wires I was able to get it running, and it ran sweet. I have now got the steering, forks wheel, etc from a GN250 Suzuki fitted, (same bearing sizes as the Honda) and the swing arm (had to spread the frame by 2mm with hydrualic jack) fitted. I bought some 'Cholins' (Chinese copy of Ohlins shocks) a while ago that turned out to be too long for the intended job but fit this beautiful.
    xl 004.jpg xl 005.jpg
    I have a smaller XL tank that should fit nicely with the right look. Have a look at some of the butchery here.
    He cut the tank mounts off.
    CJ250 002.jpg
    He 'bobed the back. Lucky the GN frame has the same mounts to reweld on.
    CJ250 003.jpg
    Footpeg mounting????
    CJ250 004.jpg
    And of course ALL the stands have been cut off. What did he think, was only going to stop by trees and walls? I was able to rescue these bits from the GN to use.
    CJ250 001.jpg
    It may not turn out 'original' but it will be back on the road again one day rather than lying unloved around the back of a shed of a person who had big ideas and no idea. :headbang:
     
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  2. Murdo

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

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    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, XL250, CBR250, ZZR250 plus a few others.
    Un f**king believeable. This was the rear engine mount bolt. It is a piece of UNC (course imperial thread) threaded rod with a metric nut on one end and a UNF (fine imperial thread) nut jammed onto the other end. Three different threads used on the one bit. How long did he think it was going to last??????? I shake my head in disgust.
    CJ250 005.jpg
     
    Last edited: Feb 14, 2018
  3. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    I guess was too much effort to find a nut that fits a threaded rod. Perhaps he thought that all threads are the same. You do love a challenge Murdo. I like the look of the CL, this will be good.
    As soon as I hear the word 'Bobber' I cringe, a refuge for the worst kind of motorcycle owner with the least mechanical skill. An angle grinder and a can of black spray paint. Then upload it to you tube to show off your customising skills followed by the mandatory listing for sale. Now where is that vomit emoticon.
     
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  4. Joker

    Joker Coming and going... Premium Member Contributing Member

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    I think we can agree that HE was the nut :p
     
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  5. Murdo

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

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    Have the rear guard from the GN repaired and rewelded to suit the Honda frame.
    xxx 001.jpg
    Sat the pipes on, but could be quite a big job the get them fitted (they are from a 450) as the angles of the head pipes are quite a bit different.
    xxx 004.jpg
     
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  6. Murdo

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

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    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, XL250, CBR250, ZZR250 plus a few others.
    As I had no back brake to fit the CB350 wheel I had available to use, I found one from a VF that had the same size brake and axel. Only problem (it was free) was that the VF has a deeper set bearing and the CB hub made it sit too high. I made this tool to shave 4mm off the back plate so it sat in the right place in the drum. The rubber hose takes up any miss alignment between the drill press and the backing plate as the spiggot keeps the correct 90 degree angle to the cutting tool.
    CTXL 004.jpg
    And the finished job. Fits like it was made for it now.
    CTXL 003.jpg
     
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  7. Murdo

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

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    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, XL250, CBR250, ZZR250 plus a few others.
    Have finished making the pipes now. I ended up using the two original head pipes, a "Y" piece and a 45 deg bend from the local muffler shop, a bit from a car and the muffler body from a Honda 250 ag-bike fitted with twin 1.25" outlets and fabricated brackets. I ran the pipes underneath the engine and up the lefthand side of the frame.
    Franks ZXR 006.jpg
    Got the tank, sidecovers and rear guard painted and stickered.
    Franks ZXR 008.jpg
    Waiting on some bits to complete the dry build before stripping the frame and painting. Rear wheel has been powdercoated and a near new tyre fitted.
     
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  8. Murdo

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

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    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, XL250, CBR250, ZZR250 plus a few others.
    The swingarm had a dent in one side and although the swingarm was straight I felt that the dent needed to be removed.
    cj 009.jpg
    Considered 1;tack welding a piece of rod and heating to pull out, 2;cutting piece out and welding in new piece or 3;bumping dent out from the back side. Went with option 3 and cut a 25mm hole in the back of the tube.
    cj 007.jpg
    Then using a 12mm bar with the end rounded to suit the curve of the tube beat the dent out. Cleaned off with the sander.
    cj 011.jpg
    Hole in backside welded closed.
    cj 013.jpg
    Painted ready to fit.
    xx 001.jpg
     
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  9. Murdo

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

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    Have been doing a bit this week.
    Got the frame sandblasted and painted, engine cleaned and painted, engine and some bits fitted to frame, start on forks tomorrow. With all the 'bolt buggery' that this poor bike has endured from the PO I have just been buying all new ones as required. Front wheel should be back from powdercoaters on Monday and then to start on a wiring harness from scratch.
    dirt ride 26-6-18 009.jpg dirt ride 26-6-18 011.jpg
     
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  10. Murdo

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

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    Fork seals were the wrong size so have ordered more (of the RIGHT size, I hope) and have been doing bits to the wiring. Sat these on for a photo.
    xx 001.jpg xx 003.jpg
     
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  11. risky

    risky risky

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    and it looked very good on thurs morning.
     
  12. TonyZXR

    TonyZXR Active Member Premium Member

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    man that's looking really nice
     
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  13. Murdo

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

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    Got the pipes painted and fitted. Still working on the wiring. :oops:
    This is my method of curing the header paint when the engine not running.
    Tamworth rally 2018 001.jpg
     
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  14. Murdo

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

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    Getting closer to a start.
    sheep 003.jpg sheep 005.jpg
     
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  15. Murdo

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

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    Got the last bits to finish the wiring yesterday and today got it down off the ramp and started. Took for a run around the block and back to reset the cam chain tension and timing. Drained the oil that had been sitting in the engine as it was unknown age or type. May still be some further tuning to be done but goes ok and idles nice. Brakes work good and gearbox selects all gears. Alternator and rectifier are doing what they should. Surprisingly the muffler is very quiet too.
    CJ finished 017.jpg CJ finished 018.jpg CJ finished 019.jpg
     
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  16. Cuda

    Cuda Member

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    As they say down here in Cornwall 'propper job, you've done a hellofa job there Murdo she looks Spankin I like the old Honda's had more than a few myself over the years G5 250's CJ's and CB's/CD's its always great to see another one rescued and given a new lease of life and you've accomplished 'that, Very nicely ;)
     
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  17. Murdo

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

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    The CJ has today gone to live with a new owner in Bega, NSW.
     
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  18. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    The big question is ... what is your next project ?
     
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  19. ShaneP

    ShaneP Well-Known Member Premium Member Contributing Member

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    Just found this thread, your work is always impressive. When I saw the photo of the pipes down the side, I was thinking apocalyptic rat bike or something you might find in Mad Max 3, not that you'd build something that looks so crude. Well done.
     

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