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Project Yamaha SRX 250 Cafe Racer

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

  1. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    What is the length and stroke of that shock Andy, I will put the info in the table.
     
  2. Andych

    Andych Well-Known Member

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    I have the figures noted somewhere Blair. I will find them and send the info to you.

    I ordered my tyres today. I opted for the Pirelli CiTi Angels.
    There was a special deal Pairs deal on eBay so I managed to get front and rear for $230 delivered.
    Slowly moving along.


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  3. Andych

    Andych Well-Known Member

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    I got the last disc bolt out so tomorrow I need to find my large cable ties and try to get these old tires off and make up my mind on what to do with the rims.

    Trial fitted the RH rear-set to check alignment for the rear master cylinder.

    I think I need to break out the metal polishing wheels and buff up these rear-sets.
    542fd5ed1ce4cac5721edf15a3cae4ca.jpg

    Problem is I don’t know what to do with the brake pedal. Do I have it chromed or just paint it?
    I need to find out from @2valve what the finish is on the NOS gear lever he has for me.


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  4. Andych

    Andych Well-Known Member

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    There hasnt been a huge amount happen since the last post.. Tyres are off the rims.. that was a pain, at least on the first one.
    Then it was time to look seriously at the wheels.. wow... they were not good.. the rear was badly etched and difficult to clean.
    I tried good old Simple Green but even a strong mix wouldnt touch this rubbish.
    You can see how bad the rim was in the pic below.. and what I used to get them basically clean. Didnt get all the etching out but it was a good start before polishing.

    UNADJUSTEDNONRAW_thumb_1228.jpg

    UNADJUSTEDNONRAW_thumb_1229.jpg

    Tyres have arrived as well as the required parts for my Triple Tree... and I hope I have figured out the best method of getting it right to suit the SRX250 frame.. the plan is to remove approx 25mm out of the stem and have it welded back together, full penetration weld with internal tube for alignment and added strength. Thanks @maelstrom for the idea :)

    My SRX4 lower triple and stem has arrived..
    UNADJUSTEDNONRAW_thumb_122c.jpg

    UNADJUSTEDNONRAW_thumb_122d.jpg

    Along with a longer front Axle to suit the wider for spacing.

    UNADJUSTEDNONRAW_thumb_1230.jpg

    And some other bits that are important.. like mirrors.

    UNADJUSTEDNONRAW_thumb_122e.jpg

    Tyres arrived..
    UNADJUSTEDNONRAW_thumb_122a.jpg

    UNADJUSTEDNONRAW_thumb_122b.jpg
     
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  5. Andych

    Andych Well-Known Member

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    Next Phase.. I started polishing up the wheel lips.. it was tough work, mainly because the degree of etching from dirt etc over many years and that I was using 100mm buffs on my polishing buff.. should really use 150mm which will cut better and also polish out better.. Still I think they have come up OK, just not to the standard I really would like. So more work to come.

    There is still residual etching there.. but a big improvement

    UNADJUSTEDNONRAW_thumb_1232.jpg

    This one shows the polished vs cleaned.. the polishing actually shows up the etching more in this shot.
    UNADJUSTEDNONRAW_thumb_1235.jpg

    The rear wheel sitting in the balancer. Finished for now..

    UNADJUSTEDNONRAW_thumb_1237.jpg

    And then the front was done..

    UNADJUSTEDNONRAW_thumb_1239.jpg

    A shot with both of them.. still plenty to do on them though..

    UNADJUSTEDNONRAW_thumb_1238.jpg
     
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  6. Mike Fulcher

    Mike Fulcher Active Member Premium Member Contributing Member

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    Man, what did you use to get such an awesome polished finish with such bad deep etching?
     
  7. Andych

    Andych Well-Known Member

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    Haha.. the camera and some sunshine hide all sorts of defects... the shine isnt quite that bright just yet..
    Another hit with some 6" buffs and it should come up even better..
     
  8. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    I feel your pain Andy,
    i've rubbed back and polished mine twice and they still need a decent rub back again with a medium density foam block to flatten off and get rid of the pitting then will need repolishing.
    I used a polishing buff with a tapered spindle arbour to suit a 6" stitched cloth or Calico buffing wheel
    I still get comment's from people saying how shiny they are

    Mine look's ok from 1 metre away but when you get close you can notice the pitting

    20180924_182605.jpg


    Bad picture quality (my old Galaxy S6) but you'll get what i mean

    20180924_182628.jpg
     
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    Last edited: Sep 24, 2018
  9. Andych

    Andych Well-Known Member

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    Yes, it is hard. Others see the nice shiny wheels but you know what they look like up close and you know what you want them to look like.
    I will get the 2 6” buff wheels in the next day or so and give them another hit.
    Then it will be time to mask them up for paint.


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  10. Andych

    Andych Well-Known Member

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    My Bike:
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    Havent done anything since the weekend.. other matters are more pressing for my time right now.. but I do have a bid in on a set of original 30X Camshafts from an XT250T. These are the Factory "hot" cam with the following specs.
    1984 SRX250 (JDM Version), XT250L (US) Intake 30X-12171-00-00 / Exhaust 30X-12181-00-00
    IN-OPEN (BTDC) 34 Degrees
    IN-CLOSED (ABDC) 62
    EX-OPEN (BBDC) 70
    EX-CLOSED (ATDC) 26
    OVERLAP ANGLE 60
    LIFT 8.3mm

    This is the Standard cams that are found in the SRX250 as well as the mentioned XT350, TT350
    XT350, TT350 Intake 48Y-12171-00-00 / Exhaust 48Y-12181-00-00
    IN-OPEN (BTDC) 30 Degrees
    IN-CLOSED (ABDC) 58
    EX-OPEN (BBDC) 66
    EX-CLOSED (ATDC) 22
    OVERLAP ANGLE 52
    LIFT (BOTH) 7.8mm

    These cams combined with the 350 plus 1.5mm bore should give it a nice amount of get up and go.. :)
    When I eventually get the engine back together..
     
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  11. Andych

    Andych Well-Known Member

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    Well I won that Auction... now to get them here and re-furb the 350 head
     
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  12. Andych

    Andych Well-Known Member

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    So, whiling away time at the hospital while my son is in here for a Clinical Trial to hopefully kill off his leukemia and I figured I should document the plans for the SRX form this point onwards.

    Paint is already established with DNA Spilt Blood Candy being the primary colour. Side covers will be piano black but I am kind of torn on the seat fairing.
    I drift between the same Spilt Blood Candy or a Metallic dark grey as per my profile pic.
    Plenty of time to decide.

    I am having a tank decal made to look as close to the factory one as possible. It want easy getting decent hi res pics of one to give to my decal guy but we managed it. I am now waiting for him to send me the proof so I can ok it. Then I will just have to wait for it to arrive from Spain.
    His work on early Honda 4 decals is amazing so I am pretty comfortable this will turn out well.

    Next is to get the steering locked away with the stem having a 20mm piece cut out and then welded back together. I am not going to do this, I will either leave it to my machinist or have another guy I know who is a certified structural grade welder do it.
    I will then be able to use the standard SRX250 bearings.
    For anyone who hasn’t read previous posts, I am using an SRX4 / 6 triple tree ( later model with 38mm fork diameter) so I can use the SRX250 3 WP (1991) instruments.
    The forks are FZR250 3LN 38mm.
    The aim is to have the bike look like it came from the factory in this configuration.

    The rest of the suspension is already sorted. I am using the 3WP swing arm to use the rear disc. I have modified an FZR250 3LN shock by changing the top pivot bush to the 3WP item. Simply push one out and push the new one in.
    Overall length is 5mm longer which should fit in with the front end being a touch longer.
    I can’t change the link ratio as these are a 2 piece cast affair so it what it is.
    The shock has been stripped down and cleaned. It still seems to have the gas charge and oil which is good. It has all been painted and reassembled ready for fitting.
    The swing arm has been blasted and etch primed ready for some paint. Still deciding on the colour but it will probably go the frame colour or the same Aluminium colour I did the fork lowers.
    The wheels are underway with polishing and once I have them to a finish I will accept I will paint the rest the same as the frame and clear coat them.
    There will still be some work to do in having spacers made to get the disks to line up as the fork Centre distance is 10 mm wider than the FZR250.
    I will also need to modify the headlight mount by shortening the bracket by the same amount that comes out of the stem.

    Next on this list is the engines, yep, plural.
    I have a matching numbers engine that runs but needs a cosmetic refurbishment. Although I do have an oversized piston ( cheers @Frankster) and a fully reconditioned head which will probably make their way into this engine along with a new timing chain and an all silver (Aluminium) paint job. The cam cover is going to be done in either Red or Black crackle finish paint as all good DOHC engines should have.
    The other engine will be the modified one.
    Cases machines for a 350 barrel bored out 1.5mm and a lovely forged piston for 9.4 compression.
    The head will be refurbished as needed and lightly ported just to clean things up and port match. It will then be fitted with the 30X Factory cams and have all new bearings, gaskets, seals, cam chain etc as well as new clutch plates and heavy duty springs as well as an XT350 carby that is undergoing much needed cleaning.
    As is the SRX250 carby.
    I still need to have an exhaust made up to get rid of the gigantic sound killer box underneath.
    I could just have new down pipes made as mine are so holy they should be at the Vatican. I just need to find someone who will bend them up. 3 local exhaust places don’t have Mandrels for that size pipe.
    I am hoping the FZR250 muffler will initially be quiet enough to pass Blue Slip.
    I also need to try and straighten out my FZR 22mm bars. Hopefully with the 10 ton press I can get them pretty straight
    Other than that, it will be lots of detail stuff. Reconditioning left and right controls, cleaning and rebuilding brake calipers and painting plus the dreaded wiring harness.
    I bought a proper 3WP harness so it should be fine with the gauges, headlight etc and it looks like it hasn’t been tampered but you just never know.
    I am tempted to strip the wrapping off just to make sure there are no broken wired etc and then re- wrap it.
    That pretty much sorts out the list I think.
    Once I have it registered or Blue Slipped on the Matching Numbers 250 engine I will hopefully Slip the 350 in and get it running on basic settings.
    I will then Dyno it to get the jetting right.

    Still plenty left to do when you write it all down lol


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  13. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Can't wait to see this come together and all the best for your son. Car-T treatment for cancer has been an amazing development.
    I think paint the swingarm the same as the frame so it looks like it looks like it belongs.
     
  14. Andych

    Andych Well-Known Member

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    Thanks Blair. Yep, Car-T here is still very limited but the technology Westmead Institute are developing will allow this treatment to be more widely available as the cost per treatment should be around $80K rather than the Novartis method costing US$480K last time I looked at their developments.

    It is going to take a while to finish the little bike though.
    My better half has to have her Gall Bladder out next week and on the 23rd October I am having a knee replacement done, I must be wearing out

    So I will be trying to get as much done before the 23rd because I don’t think I will be much from then till after Christmas.
    I guess I can at least organize all my pictures and write up in detail what I need to do.
    That way I can have a plan and tick stuff off. Might stop me from changing my mind as mischief too


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  15. TonyZXR

    TonyZXR Active Member Premium Member

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    It should be a little rocket with those engine specs when it's done! All the best for your sons recovery @Andych
     
  16. Andych

    Andych Well-Known Member

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    One of the smaller issues I have been having is to find a Tank Decal for the 3WP tank.
    Of course they are non-existent now as a new item and it has been very tough to even get a good picture to have them made.. until now.
    I managed to contact a guy from a Facebook group in India (I think) and he took a couple of pictures for me that were good enough for the Guy who has done decals for SOHC UK group for a while now.. his work is really good. Only problem is he is in Spain..lol.
    Anyway... last night he sent me a pic of the sample Decal he has made and it is pretty much perfect... so, one more item ticked off the list.
    I cant paint now until I have the decals but thats OK.
    SRX Decal.jpg
     
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  17. Andych

    Andych Well-Known Member

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    I did a little more polishing today.. tried the larger 150mm buff wheels on the front wheel.. .it came up a bit better but not enough for me to re-do the rear as well.
    I did sand out and smooth off the visible surfaces of the swing arm and then prime it.. I just wanted the surface to be nice and smooth..
    UNADJUSTEDNONRAW_thumb_123f.jpg

    While I had the polishing gear out I figured I would see how the rearsets came up polished rather than painted..
    UNADJUSTEDNONRAW_thumb_1240.jpg

    Yep... these will look the ducks nuts polished up.. there is a new gear change pedal coming but I am having issues with that bolt.. it is a bit special and no longer manufactured.. Hmm but I may have a lead on one.
    UNADJUSTEDNONRAW_thumb_1241.jpg
     
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  18. Andych

    Andych Well-Known Member

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    Decided to have an easy day today.. so I thought cleaning and masking the front wheel ready for paint wont take long... what a Pain in the Rear that is.. lol
    Anyway once that was done and I decided that the swingarm was going to be the same color as the frame as well as the wheels I prepped the swingarm and set about laying on some metallic charcoal paint to both items.

    UNADJUSTEDNONRAW_thumb_1243.jpg
    UNADJUSTEDNONRAW_thumb_1246.jpg

    UNADJUSTEDNONRAW_thumb_1245.jpg

    UNADJUSTEDNONRAW_thumb_124a.jpg

    Then I started a little bit of pre-assembly just to see what nuts, bolts, washers etc I had or need..

    UNADJUSTEDNONRAW_thumb_1247.jpg

    UNADJUSTEDNONRAW_thumb_1248.jpg

    That will do me for the day.. I would love to gets it to being a roller before my Knee replacement but I am not sure I will get that far.. still I like the way it is coming together.
     
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  19. Andych

    Andych Well-Known Member

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    Well it looks like things are starting to fall into place for me on this little project.. I was just checking to see if the Speedo gear unit for the front wheel was the same on a 3WP as the FZR250 3LN1 and it was a different part number... Grrrrr.
    Then I thought, hang on, I have a speedo from an SRX6 (same shape etc as 3WP but higher top speed) so I looked at the part number for the SRX6 and YAY.. the speedo gear unit from the front wheel is identical to the FZR.. so my speedo should read correctly.. I dont think it will get to 180kph but that doesnt matter.
    Now I need to refurbish the instrument cluster, I cant pull the gauges apart (well I could but I wont) so I need to paint the bracket and then cover the face plate.. there is one in Japan that has been done with Carbon Fibre wrap that looks good.. and I have some of that too.. no harm in trying I guess.

    SRX6 Instruments.jpg
     
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  20. 2valve

    2valve Well-Known Member Premium Member Contributing Member

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    Andy. I think i have a spare pivot bolt for the gear lever. I'll will look if you haven't already arranged one , i can send it with the other goodies.
     

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