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Project Yamaha SRX 250 3WP

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

  1. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    1987 Yamaha SRX250, Honda 1974 SL125 K1, Honda CB400SF (NC42), 2022 Triumph Tiger Sport 660
    I went to the Albury Bunnings today to look for the paint and zero stock... they checked on their system and there are 18 cans on order but the last 3 shipments have not had any included...I then checked with 3 other somewhat local Bunnings and they are all the same.... So I will take a piece I painted before to a paint shop tomorrow and get them to mix me up a few cans.
     
  2. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    Spent the weekend doing lots of fiddly stuff om the SRX...
    Started with finishing painting the rim... then cleaned up one of the Dukati brake rotors and masked it all up..did I mention I hate masking disc rotors...
    Turned out ok though... Wheel and disc together... just waiting on a 90 degree tubeless connection and I can then mount the new tyre.
    IMG_6573.jpeg

    Paint turned out slightly darker than I wanted but it will have to do.. I guess I can mask up the rear and paint it to match if it looks really out of place.
    IMG_6574.jpeg

    Sorted out the Instrument bezel..I just need to get some superglue to finish mounting the idiot light covers after polishing them up..
    Ignition is mounted as well.. I cant finally bolt it in until I get the headlight bracket back from the chrome plater... that could be an eternity.. he has had SL125 geat since December and still hasnt finished it.. grrrr
    IMG_6575.jpeg
    Slotted the Fuel filler cap on to keep the tank clean... lol
    IMG_6576.jpeg

    I also finished off the footpegs and did the brake and gearshift levers... as well as refurbished the rear brake Master Cylinder but didnt get pics of them..
    Just all fiddly jobs.. the hardest part is finding the bags with all the appropriate bits for what I wanted to do... lol

    I have a bit more wiring to sort out for the headlight... then connect up a battrey and check out all the functions.. still plenty to do but moving forward.... slowly.
     
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  3. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    I fell like I am finally getting somewhere with the SRX.
    Front tyre fitted, easy as pie with a little warming up and a few cable ties.
    I am waiting for some weights to co e but it is pretty close to balanced without any. I have marked where it needs to go so that is easy done.
    Rear brake master is assembled and connected up to the pedal. All works as it should

    Wheel bolted up and front guard mounted, caliper mount still to be done but it now looks like it should.
    Still lots to do but now I am enthused a bit more.
    [​IMG]
    [​IMG]


    Sent from my iPhone using Tapatalk Pro
     
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  4. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    Started chasing down electrical connections today... testing etc and I seem to have a RH front indicator connection missing... I am going to have to try and translate the 3WP Manual wiring diagram.. that will be fun.
    Time to order a battery for it too I think... LIon Booster packs dont like being used as a power source for testing.. well at least I dont think they do from the noises it was emitting :)
    I also put the correct rear fairing on (Mocking it up... thats my excuse) and cable tied the belly pan on as well.. just to get an idea of how it will sit and look...
    IMG_6582.jpeg
     
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  5. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    I have been scanning pictures of 2nd hand wiring looms from Yahoo Japan auctions (generally better pics than the buying sites) and using coloured pencils to follow the wiring on a photocopy of the manual and I realised there were 2 wires missing... but both were earths....so I have peeled back some of the sheath and low and behold... 2 black cbales have been snipped off and they were tucked back under the tape on the sheath.
    Its too cold to dig out the multi meter tonight but I will do that tomorrow afternoon and make sure they are the correct cables... easy fix if that is the case.
     
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  6. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    I decided to pull apart one of the handle bar switch blocks to see if I could bring a bit of life back to the rocker switches...
    Easy enough to disssemble.. cleaned it all up and dragged out the Airbrush and airbrush compressor...
    The colour isnt quite right but is certainly better than it was... I will maybe give it another coat tomorrow and then clear coat them...
    Before
    IMG_6583.jpeg
    IMG_6584.jpeg

    After
    IMG_6585.jpeg
    IMG_6586.jpeg

    Now I will need to do the RHS as well :)
     
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  7. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    My Bike:
    1987 Yamaha SRX250, Honda 1974 SL125 K1, Honda CB400SF (NC42), 2022 Triumph Tiger Sport 660
    So.. I took this week off to try and make some headway on the bike.. (in winter... what was I thinking)
    I have painted and reassembled the LH switch block, fitted up the battery and started checking all the systems.
    Both flasher units I have dont seem to work... 1 just brings on the appropriate side and doesnt flash, the other buzzes and then the light slowly comes on but doesnt flash.. I will try Repco tomorrow... Made up a side stand switch bypass and then started checking all the fittings and connections on the engine prior to trying to turn it over....
    That was when I found the bike is fighting me every step of the way... Last item to check was the oil feed line up to the head.
    This is an external line as I have converted the engine over to a 350. So cylinder, head carbys are all TT350 items.. this also necessitated using a TT350 clutch casing to enable the external oil feed for the head.
    Long story short... the banjo bolt on the head peeled out the thread... pretty much all of it just came straight out...
    I am sure our next door neigbours learned some new words late this afternoon...talk about frustrating and annoyed...
    Best case scenario will be Engine out and carefully install a helicoil insert... engine back in and try again.
    Worst case will be having to source another cylinder head... or short term I throw the original engine in (it has had a top end overhaul) while figuring out what to do on the 350. IMG_6619.jpeg
     
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  8. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Can't put a helicoil in?
     
  9. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    No room with the engine in the bike to drill the hole out... engine out... should be OK to use the helicoil... it is just time consuming.. having to protect frame paint (again) engine paint (again) for effectively a 20 or 30 minute job.
     
  10. jmw76

    jmw76 Well-Known Member

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    Longer bolt that picks up on the remaining threads deeper in the hole? Just do not do it up as tight again.
     
  11. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    It is a Banjo union and I dont know you can get them any longer than the one's I have now... plus I dont trust the thread that is in there.
    It had only ever been done up loosely to stop crud getting in. Didnt spot it before as I didnt do the head, it was done by a shop in Sydney. The head was assembled onto the engine in the frame.. but now it would be easier to remove the engine, shouldnt take too long.. "famous last words".
     
  12. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    You know you have to do it or it will just haunt you. Trouble sleeping, bowel problems, loss of appetite, all traced back to that nagging thread. :)
     
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  13. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    I have all those already... but yep... it has to be done and done properly, so engine is coming out.
     
  14. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    I spent about an hour today starting to get it all ready for the engine to come out... most of that time was getting the carby's off... drop the airbox back and away and it is still a biatch to get them off... exhaust off...generator cover needs to come off next so the starter motor can come off.. not really necesssary but makes it lots easier.
    Then the air scoop on the rocker cover comes off and it will be ready to jack up and hopefully come out nicely without damaging any paint... plenty off toweling and bubble wrap.
     
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  15. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    Quick update... Engine came out easy enough on the weekend..
    This is what I was left with in the oil feed hole
    IMG_6645.jpeg

    IMG_6619.jpeg

    While searching for something else in my multitude of black platic tubs marked "Tools" I happened across a full kit of Helicoils (well the Chinese generic version) and low and belold... there happened to be an M10 x 1.25 setup in there...
    So after very carefully plugging the feed into the head with a filed down screw and some plasticine I managed to drill out more than enough thread and using grease on the tap.. I tapped it out ready for the insert.
    Well cleaned out afterwards with thinners... dried and double checked for any swarf (nice and clean), then some locktight onto the insert and I woulnd it in.. snapped off the end carefully and withdrew it with a magnet (lucky the SS had some residual magnetic grab) and it is almost ready to go back in...
    I have some paint touchup to do and while it is out I will probably paint the Yamaha on the clutch cover... I just need to find a nice fine pointed artist brush.
     
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  16. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    Well I know that I will never be a famous Pin Striping artist... but the Clutch cover now has some red paint abd then several coats of clear on it...
    Engine is now back in the bike and the process will begin again next weekend.
    IMG_6654.jpeg
     
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  17. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    I finished drawing the first iteration of the Mounting bracket for the "Brembo" caliper.
    I sent it over to a friend to Print off on his 3D Printer so I can do a trial fit and them resolve any fit up issues etc.
    It is a very simple design... hopefully it all works out first go but probably wont lol


    Brake Bracket v1.png
     
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  18. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    love that simplicity in design, I've seen some really convoluted caliper brackets hogged out of billet that look like a lot of work, a lot of material and lot of $$
     
  19. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    OK, after getting my 3D print and trial fitting it I was really pleased with how it mated up to the fork caliper mounts but.....It wasnt thick enough in the centre (it sat too low between the mount lugs) and I needed to adjust the overall thicknes a touch as the spacer I had used to set my distance was only 5mm, I was sure they were 6mm and surprisingly 1mm makes a difference :headbang:

    So a bit more measuring and lots of frustrating fiddling with Fusion 360 and I think I have a better version.
    Brake Bracket v3.png
    This one will mean all 3 bolts will be the same length and it should blend better into the lower fork.
    The first one was printed in ABS with him thinking it needed to be tough... I will get the next one done in PLA to be more accurate and little to no warping...
    Once I am happy with what I have I will get it CNC machined from high strength Alloy and possibly Black anodised to look similar to the Caliper.
    I might even wait a little while as I also ordered a 3D Printer today...
    https://www.elegoo.com/products/elegoo-neptune-3-fdm-3d-printer
    It looks to be a good starting point....
    I have a few ideas on things I want to do with it... and having your own is far better than relying on someone else to print stuff for you..
     
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  20. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    I actually started on prepping and painting some of the panels etc last weekend.
    I searched for the right metalic grey I wanted and decided that a Mazda colour... Meteor metallic grey with pearl was the one I wanted. It is probably a little darker than I would have liked but it is a spectacular colour in the sun.
    So far I have done the 2 infil panels at the front (under the tank), the headlight bucket and the small centre piece in the tail fairing.
    Interesting in that the centre piece for the rear fairing was just a test. I painted straight over one I had done in the Candy Red I am using (DNA Spilt Blood) and even with 3 coats of basecoat there is a nice red tinge showing in the finished item. I will trey to replicate that on the 2 side pieces...
    They have all been finished in an Acrylic 2K Clear. The hardener is already in with the paint and is only activated when it hots atmosphere... pretty happy with the gloss and finish on these bits.
    More will be done on the weekend. I have "real" 2K clear for the tank as I am not sure on the Acrylic 2K's resistance to fuel.
    Not sure if I will get to the tank this weekend though.
    IMG_6677.jpeg
    IMG_6678.jpeg
    IMG_6679.jpeg
    IMG_6680.jpeg
    IMG_6681.jpeg
     
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