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Project Yamaha SRX 250 Cafe Racer

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

  1. 2valve

    2valve Well-Known Member Premium Member Contributing Member

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    I like the brushed alloy style more as it's an old school bike and the carbon one look's to modern. But this is only my view though. Since the bike is going to be stored in my shed anyway , can you fit the brushed alloy style please. Thank you.
     
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  2. Andych

    Andych Well-Known Member Premium Member

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    Haha, keep dreaming Gary
    Appreciate your input though


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  3. Frankster

    Frankster See the World before you leave it Staff Member Premium Member Ride and Events Crew

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    CF look for me.
     
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  4. Andych

    Andych Well-Known Member Premium Member

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    I must admit... I am leaning towards the CF look as well, plus "Her Inside" prefers it as well.

    I started pressing bearings into engine cases this afternoon.. once I had identified them all and selected the first lot to go into the freezer for a bit of a chilling :)
    Makes it all a bit easier that way.. having the press helps too :)
     
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  5. Andych

    Andych Well-Known Member Premium Member

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    While my bearings for the other side of the crankcase are freezing I am enjoying reassembling the transmission NOT
    I remember now why I dont like horizontally split crankcases.. stupid fiddly things.. I was even forced to refer to the Workshop Manual :mad:
    Then I realised I had the shafts the selector forks slide on around the wrong way.. that might make a difference :headbang:
     
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  6. Andych

    Andych Well-Known Member Premium Member

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    Who would have thought that reading the manual has the transmission in and working in all gears, in 10 minutes where I have spent 2 hours previously struggling because I thought I knew how it went together.

    5b062dc0ec8247fdc5401602ce528e58.jpg


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  7. Andych

    Andych Well-Known Member Premium Member

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    Crankcases are all bolted together after a nice smear of Yamabond.. all torqued down as per the book. I checked the clutch friction discs and they have a heap of meat left on them so they are all good.. I just need to soak them in some oil as it has been about 2 years since they were actually in oil.. they seem oily but a soak wont hurt them.
    I also need to sort out the clutch cover and stator cover so I can seal it up and keep it dirt free until I get the barrel bored and the head reconditioned.
     
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  8. Murdo

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

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    I've never worried about pre soaking clutch plates, they sit in oil in the cases anyway.
     
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  9. Andych

    Andych Well-Known Member Premium Member

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    Hmm I guess so, although I won’t have any oil in there until I finish bolting it together but I will apply oil liberally when I assemble the clutch side. That should be good enough.


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  10. Andych

    Andych Well-Known Member Premium Member

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    Seems today has been a good day... crankcases went together without to many issues (other than me not looking at the manual... I should have RTFM) then I get a message that my Japanese exhaust downpipes have arrived at the warehouse (just waiting on the Clip-on's now) and when I checked my IMPEX account all the items (18 of them) were in stock so they should ship in the next day or so and be here for next weekend :)
     
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  11. Andych

    Andych Well-Known Member Premium Member

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    Pretty much as far as I can go on the bottom end right now.. I still need to fix the Clutch cover so that can be bolted on..
    Tomorrow I will sort out some brackets so I can mount the Original (numbers matching) engine onto the engin stand and get the head off so I can use the valves etc to rebuild the 350 head. Good thing I have a reconditioned 250 head to go back on the numbers matching engine.. one step closer :)
     
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  12. Andych

    Andych Well-Known Member Premium Member

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    I didnt seem to get much done today.. but I did manage to put the matching numbers engine on the stand..
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    It will be nice and easy to swap the head over like this as well as cleaning it down and painting it.. I drained the oil out this afternoon and it actually wasnt too bad.. there were no nasty items in the filter screen or metalic bits on the magnetic sum plug so that is a bonus.

    I actually got a little lucky today.. I found yesterday there was 1 washer / Spacer that had done a runner.. I know I pulled it out of the engine and by rights it should have been in the same tray as the other items from that side of the crankcase.. but it wasnt.. I could have purchased it from Yamaha.. US$8 plus freight.. but I scoured eBay and happened across a guy in Newcastle selling various engine bits from a TT250... scored said washer / Spacer for $10 delivered which is fine by me.

    I also found yesterday when using paint stripper on my clutch cover and cam chain tensioner that the tensioner had been glued together.. apparently the pain stripper melted the glue as well as the paint.
    US$97 each for an OEM replacement.. and around $50 for a good quality manual tensioner.. not that I like them.. I prefer the factory automatic unit.
    I also found one of those on eBay.. he wanted $35 and I offered $30 and won it... so I have all the parts coming to almost fully button up the bottom end.
    I just need to sort blanking off the oil tube.. The guys at Gas N Gear seemed to think I might get away with my Propane burner as it was a small area but I couldnt get the material to flow on a test piece.. so I need to get a MAPP burner.. I will sort that out during the week.. another tool I will no doubt find more uses for in the future :)
     
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  13. Andych

    Andych Well-Known Member Premium Member

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    I have been drawing up a little trolley tonight so that I can sit my Blasting cabinet on it.. and have my shop-vac underneath.
    It will be far easier to use that way.. and I can roll it to the back of the Garage when not in use. It is pretty simple really.. I am going to use a Dolly from Bunnings (it is similar price as making a base and buying 4 castors) with 4 75x75 uprights and some 75x20 around the top so it wont slide off.. I am probably going to get a better gun and mount a water trap on the side.
    It will also make it easier to change the media as a side benefit..

    I also need to remove the sharp corner from the foot pump on my lift table.. I have cut my leg on it several times now and I am fed up with having to tape a microfiber cloth over it.. or I could convert it to air over hydraulic.. Hmmmm.
     
  14. Andych

    Andych Well-Known Member Premium Member

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    OK.. so my 350 conversion hit a small snag the other day when I went to have the barrel bored.. it is already oversize and it needs to go to the next oversize to remove some watermarks in the bore.. So my you beaut Wiseco piston is too small..
    I have been doing some ringing around and there are quite a few Barrels around I can get..the only problem is that the ones that are a half reasonable price and are standard bore they want silly money for.... one guy was nearly $400 by the time I shipped it here.. the cheaper ones are all bored out already (and worn out) to the same size as mine or worse.
    So I have 2 choices.. buy a new Oversized piston set (Wossner are around $240 from the engine guy) and sell my existing piston or order a new Liner for about $210 and have it fitted, then bored and honed to suit my piston.. the extra cost of swapping out the liner (apparently the Yamaha thumper liners are a PITA) takes it out past the price of the replacement Piston..
    I am not going to do anything till next week as I am waiting for my engine guy to give me a lead time on the liner.. just to see but it looks like I will go with a new piston set.. That will teach me to not take everything on face value and to measure and double check things first...
    Still I have plenty still to do without the barrel.. and Saturday is looking to be a nice temp..
     
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  15. Andych

    Andych Well-Known Member Premium Member

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    So.. finally got out into the garage today.. a much more sane 30 degrees.. I spent the best part of an hour trying to get 2 studs out of the 350 head.. do you think they would move.. not at all.. and that was after heat.. penetrating fluid (WD40) a cheap stud extractor that failed so miserably I threw it in the bin..
    Tried the old reliable 2 nuts locked up onto each other.. nope.. would not budge at all.. I even contemplated welding a nut on and getting new studs..but decided against that method.. I wasnt that desperate.
    I will be heading down to Sydney Tools on Monday and buying this..https://sydneytools.com.au/product/...dP49PqDj0bL7iWBbpfSC9eoYquHzz96YaAkjEEALw_wcB
    I am sure I will need to use it again... maybe lol.

    I also removed the forks and triple trees and flipped the frame upside down so I can finish the rear shock and swingarm install properly as well as fit the centre stand and side stand.
    I then started to look for the side stand.. lol. Couldnt find it so I decided I had had enough for the day.. the bike didnt want to play nicely so I left it in the dark.. maybe it will behave tomorrow (if I dont go to the swap meet that is).
     
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  16. Andych

    Andych Well-Known Member Premium Member

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    Today was a good day thanks to @2valve . He put me onto a very nice dead stock sized (85.89mm) barrel at a very reasonable price.. so disaster averted on that front.. lol
    It should be here later in the week all things being equal.
    Plus my bits from Japan turned up.. handlebars are exactly what was needed and the exhaust downpipes look like they will be fine for what I need to do with them.
    Time to sort out the front calipers so I can get the spacers made up for the front end.. then I can start bolting stuff together properly.
     
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  17. 2valve

    2valve Well-Known Member Premium Member Contributing Member

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    No problem buddy , more than happy to help out.
     
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  18. risky

    risky risky

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    aldi has some small moving trolleys at 15 bucks. might be cheaper than buying 4 castors?
     
  19. Andych

    Andych Well-Known Member Premium Member

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    Well I did say a short while ago that I wasnt going to do anything in the Garage today.. but I had to go out there to see if I had any decent fuel for the lawn mower (no I am not mowing the lawn today.. I might look stupid but not that bad) and decided for some inexplicable reason to lift the rocker cover off the matching numbers engine... just to see what it was like under there.. you know.. looking for sludge etc.
    Well blow me down.. it looks pristine.. actually it looks like it has never been touched. no sign of spanners being on the cam bearing caps or the cam sprockets... I will pull the plug and stick my camera down there for a look.. I might even get myself a compression gauge and hook the starter up to check compression.
    I am now starting to feel a little reluctant to pull the head on this baby.. I will drop the clutch cover off as well, just so I can get a better idea of how it is..
    I was going to use this head as a donor for the 350 head in terms of Valves, valve springs etc but... I am thinking now that I really dont want to disturb what looks like a really good engine.. it did run nicely before I pulled it out of the frame..
    I kept it as it is matching numbers to the frame... maybe I just clean it up.. paint it, maybe put in a new output shaft seal...
    I will take some pics maybe tomorrow or Monday (its too hot today) and make up my mind from there..
    I do have a fully refurbished head from my original engine (now the 350 hybrid) that hasnt run.. it is easy to drop everything out of that one.. and the valves are already faced.. just needs the head to have the seats cut, new stem seals, faced and assembled.. .
    I will wait and see what I think..... hmmmm
     
  20. Andych

    Andych Well-Known Member Premium Member

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    Well after a nice little storm it cooled down enough for me to head out to the garage at 8.30 (I was not too interested in the tennis) to see what the internals of this engine look like.. only to find my wireless endoscope was all out of battery.. so I pulled the clutch cover off to have a look...
    I am not sure if this engine has been apart or not... I mean it has capscrews all around replacing the JIS screws and the clutch cover gasket came off really easy.. and intact so presumably it was installed with a smear of grease.. you can see in the pictures that the locking washers on the crank end and the balance shaft look brand new. The other telling item is the oil feed tube normally has witness marks where they have been roughly removed with long nose pliers.. it did come out reasonably easy though so it may not be an indication..
    The cam covers have a little paint daub on each one.. not sure why.. maybe to say they have been torqued???
    The only things I can see at present are there oily sludge (not much really) left in the bottom has a slightly metallic tinge to it and when I turn the engine over with a socket (no plug in) it rolls off TDC by itself depending on where the balance weight is.. which may indicate no ring tension.. I will hopefully get a better idea tomorrow when my endoscope is charged up and I can get a look at the bore...

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