1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

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

    Messages:
    5,104
    Likes Received:
    4,008
    Trophy Points:
    1,148
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    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
     
    • Like Like x 3
    • Love it! Love it! x 1
  2. Murdo

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

    Messages:
    5,104
    Likes Received:
    4,008
    Trophy Points:
    1,148
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    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 bought 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
     
    • Nice Work Nice Work x 3
    • Like Like x 1
    Last edited: Oct 4, 2019
  3. Murdo

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

    Messages:
    5,104
    Likes Received:
    4,008
    Trophy Points:
    1,148
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    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.
     
    • Nice Work Nice Work x 4
    • Winner Winner x 2
    • Like Like x 1
  4. Murdo

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

    Messages:
    5,104
    Likes Received:
    4,008
    Trophy Points:
    1,148
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    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.
     
    • Like Like x 1
  5. Murdo

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

    Messages:
    5,104
    Likes Received:
    4,008
    Trophy Points:
    1,148
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    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
     
    • Like Like x 2
    • Nice Work Nice Work x 2
    • Winner Winner x 1
  6. Murdo

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

    Messages:
    5,104
    Likes Received:
    4,008
    Trophy Points:
    1,148
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    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.
     
    • Like Like x 2
    • Nice Work Nice Work x 1
  7. Murdo

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

    Messages:
    5,104
    Likes Received:
    4,008
    Trophy Points:
    1,148
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    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. :)
     
    • Nice Work Nice Work x 3
    • Winner Winner x 2
  8. Murdo

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

    Messages:
    5,104
    Likes Received:
    4,008
    Trophy Points:
    1,148
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    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
     
    • Nice Work Nice Work x 3
    • Winner Winner x 2
    • Like Like x 1
  9. Mike Fulcher

    Mike Fulcher Active Member Premium Member Contributing Member

    Messages:
    118
    Likes Received:
    35
    Trophy Points:
    53
    Joined:
    Feb 3, 2018
    Gender:
    Male
    Occupation:
    Owner of Mikes Chainsaws & Outdoor Power Ltd
    Location:
    New Plymouth New Zealand
    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

    Messages:
    5,104
    Likes Received:
    4,008
    Trophy Points:
    1,148
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    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
     
    • Like Like x 2
    • Nice Work Nice Work x 1
  11. Murdo

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

    Messages:
    5,104
    Likes Received:
    4,008
    Trophy Points:
    1,148
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    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
     
    • Nice Work Nice Work x 5
    • Like Like x 4
    • Agree Agree x 1
    • Informative Informative x 1
  12. Murdo

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

    Messages:
    5,104
    Likes Received:
    4,008
    Trophy Points:
    1,148
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    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
     
    • Nice Work Nice Work x 4
    • Like Like x 2
  13. Murdo

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

    Messages:
    5,104
    Likes Received:
    4,008
    Trophy Points:
    1,148
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, XL250, CBR250, ZZR250 plus a few others.
    After getting nearly caught in the dark last weekend I have been thinking on how to put some better lighting on the XL. I thought about using one (or two) of these 18 watt LEDs as the original headlight is a 35 watt, using a by pass switch to turn high beam off when using the LED.
    https://www.ebay.com.au/itm/Truck-S...e=STRK:MEBIDX:IT&_trksid=p2060353.m1438.l2649
    As the original system is 6 volt AC I will need to use a rectifier to DC and a 6 to 12 volt converter to run the LEDs.
    My question to you all is would doing it this way work, and just how bright is 800 Lumens compared to wattage in a bulb?
     
    • Like Like x 1
  14. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

    Messages:
    3,418
    Likes Received:
    2,344
    Trophy Points:
    923
    Joined:
    Dec 23, 2012
    Gender:
    Male
    Location:
    Thailand
    Home Page:
    My Bike:
    Yamaha FZR400 3TJ1, Honda MC22
    I know nothing, but I bet just one of those LED lamps would be enough.
     
  15. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

    Messages:
    3,606
    Likes Received:
    2,066
    Trophy Points:
    898
    Joined:
    Jun 18, 2016
    Gender:
    Male
    Occupation:
    Panel Beater, Spray Painter, Custom Fabricator
    Location:
    Adelaide, South Australia
    My Bike:
    Yamaha's, 1990 FZR250R 3LN3 , 1986 XT250TS 57R , 1984 IT200L 43G
  16. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

    Messages:
    3,606
    Likes Received:
    2,066
    Trophy Points:
    898
    Joined:
    Jun 18, 2016
    Gender:
    Male
    Occupation:
    Panel Beater, Spray Painter, Custom Fabricator
    Location:
    Adelaide, South Australia
    My Bike:
    Yamaha's, 1990 FZR250R 3LN3 , 1986 XT250TS 57R , 1984 IT200L 43G
    Wiring them up shouldn't be a problem, you don't really have to use a rectifier as led's will work the same on AC or DC.

    I haven't looked at a XL250 wiring diagram, does it use a seperate regulator and rectifier ?
    And is the regulator a full wave or half wave type ?
    Some bike's you can simply add in a 12v reg/rect and convert it to 12v just by that (need's 12v battery and bulbs, flasher etc)
    The voltage output can be a little lower at idle, but come's good over 2000 rpm's


    Another option is you could swap out your lighting coil for a 12v, if you have the lighting coil mount dimension's i can compare it to a pit bike one, they are pretty good and it was not far off the dimensions of a Yamaha IT one i had.
    Swap it in and add a 12v battery, a 12v reg/rect, 12v indicator and stop/tail and dash bulb's, and a 12v flasher relay, the horn will be fine with 12v (will work better than on 6v)


    Is your headlight a 5 3/4", if you don't mind the look you could use one of these Led conversion light's
    https://www.ebay.com.au/itm/5-75-in...453859?hash=item2cefa9f4a3:g:3b4AAOSw5xpbbpvQ

    LED Power: 45W/High Beam,30W/Low Beam
    Lumens: 4000LM//High Beam,2800LM/Low Beam
    LED: Osram LED Chip



    s-l1600.jpg

    There are a couple of angel eye type led headlights available too, so you could use the outer led ring as a parker,
    the outer ring has a turn signal wiring option too so it changes from white to amber but i wouldn't use it
    I think the top link light would be better due to having 2 projector led's for high beam

    Both of these are available from ebay Australia too but are 30% dearer

    https://www.ebay.com.au/itm/5-75-Pr...a=0&pg=2047675&_trksid=p2047675.c100005.m1851

    s-l1600.jpg
     
  17. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

    Messages:
    3,418
    Likes Received:
    2,344
    Trophy Points:
    923
    Joined:
    Dec 23, 2012
    Gender:
    Male
    Location:
    Thailand
    Home Page:
    My Bike:
    Yamaha FZR400 3TJ1, Honda MC22
    I was waiting for @my67xr to come to the rescue
     
    • Agree Agree x 1
  18. Murdo

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

    Messages:
    5,104
    Likes Received:
    4,008
    Trophy Points:
    1,148
    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, XL250, CBR250, ZZR250 plus a few others.
    Thanks for all that my67xr.
    The system runs a single wire from lighting coil to hi/low switch to bulb. I will have to take the bulb out and do some measuring.
    I thought that LEDs would only work with DC? That was why I was told to use a rectifier in my CTXL trials bike build to run the tail/brake lights.
    Looking to just fit an extra light that could be easily removed if damaged and still have a working original. More thought required.
     
  19. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

    Messages:
    3,606
    Likes Received:
    2,066
    Trophy Points:
    898
    Joined:
    Jun 18, 2016
    Gender:
    Male
    Occupation:
    Panel Beater, Spray Painter, Custom Fabricator
    Location:
    Adelaide, South Australia
    My Bike:
    Yamaha's, 1990 FZR250R 3LN3 , 1986 XT250TS 57R , 1984 IT200L 43G
    I tested my spotlight's out with a garden 12v AC 20A power supply and they work fine
    I also have an automotive 20" 200w Led lightbar for lighting up my backyard that i have been running off the same power supply for a few year's now
     
    • Thanks! Thanks! x 1
  20. Andych

    Andych Well-Known Member Premium Member

    Messages:
    2,466
    Likes Received:
    1,450
    Trophy Points:
    798
    Joined:
    Oct 6, 2016
    Gender:
    Male
    Location:
    Sydney
    My Bike:
    1987 Yamaha SRX250, Honda 1975 CB400F, Honda 1974 CB250 G5 ?
    12v Garden power supplies are DC voltage out... Single phase AC power in. Pretty much the same as PC Power supplies, Laptop power supplies etc. At 20 amp it will light up quite a few LED lights :)
     
    • Agree Agree x 1

Share This Page