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Project Honda XL250s 1979

Discussion in 'Your 250cc Projects' started by Murdo, Jan 13, 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 about six months ago but have only just got around to working on it. I bought from the original owner who had bought it in Sydney, NSW in 1979. It was registered for the first year but when he moved back to the family property at Coonabarabran, NSW he let the rego expire. It remained on the farm until he moved to Tamworth in 2016, when he advertised it for sale. We did a deal for the bike and some spares he had gathered over the years and I brought it home. It has had a few knocks and dents, some dodgy replacement bits and many years of dirt and sheep sh*t, but it only shows 4,400Km on the speedo which I believe to be true.
    phone photos 161.jpg phone photos 162.jpg
    Have replaced the handlebars (originals bent and cracked), washed years of crap off, lubed all cables, heated and straightened footpegs, bent sidestand back into correct position, etc. Have ordered new air filter, mirrors, tail light, bulbs, etc. The seat cover is original and the paint work and plastics not too bad. Has near new tyres and the chain and sprockets will go a bit longer yet. Engine runs sweet and will be getting an oil change, valves set, new plug and carb clean to make sure it is running it's best.
    The standard muffler had rusted out years ago and some 'farm welding' had been applied to it to stop it scaring the sheep, but it needed some attention to bring it up to the standard of the rest of the bike.
    Tammie visit -XL250s 008.jpg
    This is what it should look like.
    Tammie visit -XL250s 007.jpg
     
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  2. 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 a piece of 75mm exhaust tube from the local muffler shop. I measured the circumference at both ends of the original and marked onto the new pipe. I cut out the 'V' with my plasma cutter to get the right diameters.
    Tammie visit -XL250s 015.jpg
    Clamped back together and welded. I bough some fence caps from the big green hardware store and cut out the centres and flanges to give me the right looking end caps.
    Tammie visit -XL250s 017.jpg
    Then cut a piece of 1.6mm sheet to seal the front end, some 32mm tube for the first tube and some 25mm for the out tube. These I welded so that they overlap to make the sound/gasses change direction twice before they escape to atmosphere, and the front plate and end cap welded on too. The sizes I had worked out years ago with other bikes seem to work the best, so used the same here.
    Tammie visit -XL250s 018.jpg
    Welded together and smoothed off.
    Tammie visit -XL250s 019.jpg
    Here with a muffler from a 250R. Look much the same to me.
    Tammie visit -XL250s 020.jpg
     
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  3. 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 cut the old bits off the bike and the fitting from the remains. Clamped into position and tacked. When happy with alignment I fully welded it all together. Some heatproof black paint and fitted the original heatshield.
    Tammie visit -XL250s 025.jpg Tammie visit -XL250s 026.jpg
    I think it will do.
     
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  4. 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.
    Damn, just realised I've put the heatshield on backwards. Job for tomorrow.
     
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  5. 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.
    Got the heat shield on the right way. :oops:
    The tool box had lost its lid somewhere along the journey of the last 40 years and needed to make another one. I found a piece of 6mm plate close to the right size and traced a line from the end of the box.
    xxx 003.jpg
    Cut out with the plasma cutter and ground smooth with flap disc in grinder. Cut some 1.6mm aluminium sheet to about 6mm bigger than box and clamped to steel plate in vice. Worked the edges over with a planishing hammer to form the edges.
    xxx 006.jpg
    Cleaned up with a file and fitted nicely. I found some 1.2mm steel strip and made some hooks to hold a strip of tube rubber and riveted to sides of box.
    xxx 007.jpg
    Some black paint, stuffed the original tools in the bag in and fitted to bike.
    xxx 011.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.
    Today I fitted new tapered roller steering head bearings to replace the 'nochy' originals. I could not find a piece of pipe/tube of the correct diameter to seat the new bearing onto the stem, but found a piece of pipe to fit the old bearing race I had just removed so I used it to seat the bearing and the pipe to drive the old race.

    Hayley on bike 004.jpg
    To put the bearing cone into the frame I used the old race to drive the cone to the bottom of the machined section. This caused the old bearing race to also stick into the frame, but a hit with the same long driver I used to get it out worked again.
    Hayley on bike 005.jpg
    Bearings greased and steering assembled, forks with new seals and oil slid into place and tightened all down. Wheel fitted ready for a ride.
     
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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.
    Went for short ride this morning and very unimpressed with the new rear shocks (remind me of a pogo stick ride) that I bought from Brisbane (have to be a Chinese copy) to replace the leaking originals. The Honda ones were never that good when new (but these are worse than the worn out ones) so back to some 1970's technical fix.
    I removed the springs and seats and drilled a 4mm hole in the bottom of the shock body.
    XL shock 002.jpg
    Tipped upside down and pumped the oil into a measuring jug. These had 110ml in each one.
    XL shock 003.jpg
    Using a 50ml syringe I refilled the body with 80w-140 gear oil, pumping the shaft to get air bubbles out as the oil was pushed in. It is important not to put more oil back in than was taken out (ie don't overfill the oil chamber) as this may hydraulic lock and push the seal out.
    XL shock 004.jpg
    I then welded the hole with the MIG welder to seal it.
    XL shock 008.jpg
    Reassembled the spring and back on the bike. I put the welded hole to the inside so cannot be seen, and after a ride through some mud will not be visable anyway.
    XL shock 009.jpg
    Now they work like shocks should. :)
     
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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.
    Needed a battery cover and unable to find one, so back to the tools.
    shane 001.jpg
    Using some 1.5mm alloy sheet I folded two flanges.
    shane 002.jpg
    Then with some cutting and snipping, a couple of folds and I had the shape.
    xl 001.jpg
    Some welds on the corners, clean off and paint and fitted when dry.
    xl 002.jpg
     
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  9. Mike Fulcher

    Mike Fulcher Active Member Premium Member Contributing Member

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    My Bike:
    85' Yamaha SRX 250, 87' Honda VT250, 86' Suzuki NZ 250, 87' Honda CBX 250, 74' Yamaha AGR100R Racer
    Thanks for your comments, nice job on the exhaust you built up.
     
  10. 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.
    After the last trail ride for the year it is now time to find out why the engine is down on compression. I fear it may be a cracked head as it has very little comp when cold (and takes a lot of starting) but gets some comp when hot and is down on power when riding.
    I took the seat and tank off and gave all a good wash so no bits of dirt will drop into the engine.
    Jack's third birthday 012.jpg
    Pipes took a bit of getting out, carb off and top of head removed. Found three head bolts came out ok but the fourth one came half way then bound up tight. I worked it back and fourth and gained a little more but as they go through head and barrel into the crankcase I didn't want to push it and snap it off. I lifted the copper washer and dribbled WD-40 down the shank of the bolt and will leave until tomorrow to let it soak down.
    Jack's third birthday 016.jpg
    While that is soaking I sandblasted the pipes and gave them a couple of coats of high temp paint.
    Jack's third birthday 020.jpg
     
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  11. 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.
    After soaking the head stud in WD40 all night I was able to get it undone a bit further and after taking the coil off was able to get the head/barrel assy off the crankcase. The stud had rusted into the dowel between the barrel and case and took quite a bit of getting off. I guess this is what happens when things get left alone for 40 years.
    xl250s 001.jpg xl250s 003.jpg
    The stud and dowel cleaned up alright and will be usable again.
    xl250s 007.jpg
    The rings were over specs for end gap so new rings and gasket set ordered. Good news was that the head wasn't cracked. The bore had glazing on some parts so a light hone to remove the glaze, bead blast the head and barrel to get off 40 years of mud/crud, lapped the valves, a through wash with strong soap and very hot water and wrapped ready for reassembly when new parts arrive.
    Oil wiped to check no honing grit left.
    xl250s 013.jpg
    Waiting for new parts.
    xl250s 015.jpg
     
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  12. 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.
    New rings arrived yesterday and got straight on to fitting them. All good end gaps so onto piston and into engine. All buttoned up with new gaskets and seal and fired and ran sweetly on second kick. Ready to hit the (dirt) road again.
    xl 001.jpg
    Loaded up my touring kit 'just to make sure it fitted'.
    xl 003.jpg
     
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