Kermit's XR250R rebuild thread

[Kermit]

Sun 14th Sept
Haven't done much today as there was too much racing on TV but managed to get a few hours in before the delayed MotoGP and just now

Suspension Linkages [partly] cleaned up
Will get the dremmel with buffer tool on them to clean up awkward areas then autosol



Removed the rest of the bits from the Swinger & partly cleaned shock
More work needed. Not sure on best method for finishing the swinger...i know dishwashers are supposed to be good for cleaning tarnished alloy but i don't have one - any suggestions for cleaning it (and the fork legs) up but maintaining a brushed/clean finish (ie not polished)?


All these bits have had the wirewheel treatment and waiting for a degrease tomorrow
Then will either get hammerite satin black (most parts), vht spray (exhaust parts) or competition black which is glossy and quite tough (top yoke)


Provisional schedule for the rest of week

Monday
Dremmel wire brush awkward parts
Degrease parts

Tuesday
Spray night....have to buy another can of Hammerite as I don't think 1 can will be enough and you don't want to run out of it half way through as the curing process starts after 4hrs iirc...then you'd have a 2 week wait before additional coats...so all in one night

Wednesday
Polishing night but I'm guessing already so will leave the schedule at that

[Kermit]

Mon 15th Sept - Part cleaning

Hammerite Rust Beater in Action
Promised to be very like the industrial Avesta Gel Gaz [from honda-forums.com] got me when i did the NC30 exhaust....doesn't smell or look as potent as that industrial stuff but the end result is the same


Parts in a bath of Gunk


Parts washed after gunk bath and drying off ready for spraying [most of them] tomorrow


Exhaust after about 3 hrs of Hammerite Rust Beater (+ frequent agitation with wire brush)
Most of the rust has indeed gone but i'll probably give it a once over the wire wheel then another coat of gel tomorrow before spraying at the weekend - the downpipes are getting blasted by the same place thats doing the frame

[meljordan]

Top job Kermit and a great photo diary, your shiny bits seem too be back to new as you were asking about polishing them honda dealers are selling stuff that smells more like bubblegum than bubblegum,its about a Tenner a pot but goes a long way.other than that its a great thread and i'm reading it with interest. cheers mel.....

[AIRWOLF]

Good stuff Kermit.

Just spotted this, as most of us have been at the national meet on dartmoor since last thursday.

Look forward to the rest of the report.

[shuriken]

fantastic thread and great will power! Now whilst I'm banned from the road maybe I should do some work on the XR600.......

[Kermit]

shuriken...you know it makes sense

Thanks for the support...here comes Tues & Weds work....


I did some work last night but didn't post cos the pics aren't great.

Tues 16th September

Parts for Satin Hammerite All prepped and ready for action


Done - needed to leave them overnight to harden a bit and now in a nice warm house which should speed up the curing


Weds 17th September

Exhaust parts (minus the headers) now all clean and ready for VHT Spray


1 mist spray...20mins...then one full coat and job done - they should cure on the bike once i get it running again


Other exhaust bits


My order of various M5, M6, M8 Stainless Steel Caphead bolts arrived + a few other s/s bits


I forgot to take my white handlebars to the powder coaters but not too bothered now as i've managed to blag myself a set of grey Renthal bar complete with Red acerbis hand protectors, renthal grips and bar protector (& CFR risers/clamps..not needed) for a half decent price. They should arrive early next week

[phil w]

Putting my XR to shame, top stuff though.
Just a question what size sprockets are on there

[Kermit]

it came with 13/48 but the seller had already bought a new 14t front as the 13t was well worn. I'll run it 14/48 when its ready and decide if adjustments need to be made unless anyone has any good suggestions?

[phil w]

Read on thumpertalk, some people say 14t fits some say it rubs??
Some say keep 13t front and go to a 45 rear equates to the same thing but gives better road manners as well as keeping good off road pull

[Kermit]

Thanks for the info as I hadn't realised 13/48 was the standard size. Will check it fits without rubbing and if not at least I'll have an excuse to buy some Renthals