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Project Yamaha SRX 250 Cafe Racer

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

  1. Andych

    Andych Well-Known Member Premium Member

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    Picked up all my machined parts today.
    The steering stem needs a little more done as the top bearing surface has been done as a press fit where it should be a slide fit but that’s easy to fix.

    The engine cases are done and the 350 barrel looks great sitting on there.

    0b034f34eeea697831a540be6d830d52.heic.jpg

    And the clutch cover has 2 new plugs in spots where there was a kick starter and de-comp lever.
    They need sanding off and cleaning them up, I might even try to round them off a little.
    I was going to try and have them blend in but it should all look seamless when I am finished.

    ed02f88d4dc9da9f3f1a92194c028e6c.jpg

    c87438e2867144fd9152fc6278b51049.jpg

    This last pic shows how tight it is to get this barrel on there. We only have enough surface where the old oil feed went up the 250 barrel for the barrel O ring but that is enough.

    21c74927e85ea5cf4e3f7b803137e6c8.jpg


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  2. Andych

    Andych Well-Known Member Premium Member

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    Picked up all my machined parts today.
    The steering stem needs a little more done as the top bearing surface has been done as a press fit where it should be a slide fit but that’s easy to fix.

    The engine cases are done and the 350 barrel looks great sitting on there.

    0b034f34eeea697831a540be6d830d52.heic.jpg

    And the clutch cover has 2 new plugs in spots where there was a kick starter and de-comp lever.
    They need sanding off and cleaning them up, I might even try to round them off a little.
    I was going to try and have them blend in but it should all look seamless when I am finished.

    ed02f88d4dc9da9f3f1a92194c028e6c.jpg

    c87438e2867144fd9152fc6278b51049.jpg

    This last pic shows how tight it is to get this barrel on there. We only have enough surface where the old oil feed went up the 250 barrel for the barrel O ring but that is enough.

    21c74927e85ea5cf4e3f7b803137e6c8.jpg


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  3. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Nice,
    you could use some JB Weld or Devcon around the plug's, then sand them back once it's dry, and even fill the 'Kick Starter' writing then sand it back flat
     
  4. Andych

    Andych Well-Known Member Premium Member

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    That was the plan.. at least for the Kickstarter writing.. I have a few other repairs on the cover as well so.... while I am at it....
     
  5. TonyZXR

    TonyZXR Active Member Premium Member

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    Wow that is definately a tight fit haha
     
  6. Andych

    Andych Well-Known Member Premium Member

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    Yes, once I get the gasket set for the 350cc engine I will look at what I need to do to ensure it is leak free.
    I can also use Yamabond with the gasket but I think the ring will manage it easily.
    I could, if I really wanted to do it, would be to plug that oil feed line so the normal gasket has full surface.
    That line is only used by the 250 for feeding the cams etc where there isn’t room on the 350 barrel for the internal oil line..the 350 uses an external oil line which is why I need to use the 350 clutch cover.
     
    Last edited: Oct 16, 2018
  7. TonyZXR

    TonyZXR Active Member Premium Member

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    i mean if it isn't being used anymore might aswell plug it
     
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  8. Andych

    Andych Well-Known Member Premium Member

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    I just need to make sure that whatever I plug it with... it will stay in there.. I have to plug the crankcase where the original oil feed comes through from the Oil Filter and that will most likely be just finding a suitable plug and tapping the hole to suit. The big hole is a different story.. I can maybe plug it on the inside of the cam chain tunnel and then fill it with devcon.. at least then I wont worry about the devcon falling out.
    I have plenty of time to think about that.
     
  9. Andych

    Andych Well-Known Member Premium Member

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    I have been doing some checking to see how the new front end will work when compared to the original SRX250.
    Some very rough measurements give me a Trail of 98.8mm where the original is 93mm
    Over the weekend I will take more accurate measurements when I mock up the front but given the changes that have been made I dont think that is too bad.. the bike should still be light on the steering and manoeuvrable, maybe not quite as good as the original but a little more stable at speed.
     
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  10. Andych

    Andych Well-Known Member Premium Member

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    Ordered a few more bits today. I decided on using a slightly higher geared 15/41 sprocket set so the 41T has been ordered from the UK.
    I also have a 350TT gasket set coming from Brisbane.
    I will need to either have an Oil line made up or buy a 2nd hand unit.
    There is one on EBay but the pics indicate it might be damaged at one bend and I don’t want to spend $55 on a piece of junk.
    55a271a06f829957dedf2f7e4574dc56.png

    I don’t have tube benders otherwise I would bend it up out of Stainless tube and then have the ends silver soldered on or I can look at having it done in stainless flex. Hmmm decisions decisions.


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  11. Andych

    Andych Well-Known Member Premium Member

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  12. 2valve

    2valve Well-Known Member Premium Member Contributing Member

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  13. Andych

    Andych Well-Known Member Premium Member

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    Yes, I spotted that one too. It does look to be in much better condition.
    I can’t remember if I looked on Megazip to see if they are still available or not.
    Might have to do that later on when I get home.


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  14. 2valve

    2valve Well-Known Member Premium Member Contributing Member

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    Andy. Pipe is a back order part via Yamaha, $82.70.
     
  15. Andych

    Andych Well-Known Member Premium Member

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    Hmmm who was that through?
    I looked at a few including Megazip and it is shown as NLA.
    As long as the part is available I would prefer a brand new item.


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  16. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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  17. 2valve

    2valve Well-Known Member Premium Member Contributing Member

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    Hi Andy. PM inbound
     
  18. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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  19. Andych

    Andych Well-Known Member Premium Member

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    I am very doubtful that I will find a new one anywhere... I have gone through all the major Motorcycle OEM Parts websites and it is shown as NLA on all of them..
     
  20. Andych

    Andych Well-Known Member Premium Member

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