Kermit's XR250R rebuild thread

[Kermit]

ok, here goes....another [possible] epic picture thread of a rebuild. I'm new here but did a rebuild a few years back on my NC30 and documented it diary style with 250+ pics on my usual forum (click here to have a look)

Now I've bought a XR250R, I've had one ride (1 more ride than i took on the NC before stripping it down) and I'm at it again

The first few posts below are catch up posts with what I've already posted on honda-forums.com but as I'm in expert Honda off-road company here, I'll no doubt be relying on you guys when i hit any problems or find my hammer isn't big enough

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Sat 6th September
Went up to Jedburgh in the Scottish borders on Saturday with the trailer. Battled through umpteen flooded roads & diversions (my 167m/3.5hr journey up turned into 240m and near on 6 hrs ) but I wasn't going to give up and finally picked the XR250R (1996 model) I won on ebay

Overall its mechanically sound but cosmetically needs a little attention and I'll elaborate on what I've already ordered and what I'm going to do to it later on.

Here's the pics

As Advertised on ebay



Stripped some of the bodywork (& Acerbis frame protectors) to give it a decent clean in order to see whats what



few bits in this pic need attention such as
exhaust, gear lever, stand, sprocket guard and probably engine casings (will respray them)



Under the acerbis frame guards fairly dirty but overall very little rust on the frame



Have already ordered replacement and more modern Decals as these ones weren't applied too well



Ready for my first proper blast hopefully later on today :d


I've already cleaned and re-oiled the air filter, checked & cleaned the plug but have ordered a new filter anyway as the current one is a bit past it.

Have also ordered a stand as I can't get my Abba or paddock stands to work with it and don't have a suitable box. Found this for £40 which I thought looked like just the ticket



The bike came with a Pouch that bolts behind rider, a new oil filter, 2 new inner tubes, some more acerbis plastics (not fitted) to protect forks/front disk, an owners manual (in French) and a new Talon front sprocket which does need fitting as the current one is getting hooked.

How long before I'm happy its tidy enough for my liking...2 weeks or 2 months?

[Kermit]

Sunday Sept 7th

I'm just back from my first run on it and not having researched where near me its legal to go off-road, I took the 12 mile trip to Ilkley where I was brought up. Unfortunately riding on the moor itself isn't allowed but there is a road known as Keighley Gate Road that goes over the top of the moor from Ilkley and down to Keighley that I used to frequent when i lived just 1/4m from the bottom of it when i was 14 and had a £30 TS50 and know thats legal given the name of it even though only proper off road bikes/cars are able to traverse the Ilkley side of it.

The Gate - this side of road from Keighley is tarmac, the other side is better



looking down towards Keighley



Half way back down to Ilkley



Skipton is over the top at the end of the valley (Wharfedale) you can see in the distance


Question...whats a good value for PSI with knobblys on the road as I read in the Honda pdf service manual I've aquired that 15 f&r is right but not sure if thats for off road/mud and I guess 80% of my use will be on road or roads similar to the above? I ask as on the road in corners the bike a few times if pushing it even only slightly went a bit "squishy" at times and did look a bit under inflated with me sat on the bike?

I am tempted to tear it down but we'll see how i feel when the stand arrives

[Kermit]

Mon 8th Sept 2008 - Ooops...feck the 2 week+ wait before stripping it.......I've started
I've actually progressed a little bit further passed this point but the lack of a bike stand stopped play



My first box of 'bits'
All will get the wire wheel treatment then either VHT Exhaust spray or my favourite....Satin Black Hammerite with the exception of the engine guard that i guess it best just cleaned up a bit.


Performance Mod #1 - Dremmel this silly ridge down a bit to aid exhaust gas flow :yes:


Ordered exhaust gaskets today, bought a new plug and have filter and a few other bits on there way....just need a few more boxes now

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posts from here on in will be posted in tandem with my entries on honda-forums.com, comments and support welcome

[Kermit]

Question re powdercoating

I'll probably get the frame powder coated as I can't stand imperfection and the sight of rust...question is, should I go for a Satin Black as tbh I'm not that keen on the white frame or maybe red?

regarding the above, the tank graphics (with swingarm gfx) I've ordered feature a darker Honda red + i'm planning to make the number boards red and will almost certainly replace the gaiters with red or black ones...so would it look ok with the frame black or red?

Does anyone know a source of 1996 model plastics just in case I go the whole hog?

[phil w]

I got the english manual and it only says 15 but agree after just getting mine the road handling is "interesting" . A lot of places I will be going I think, although rutted and stoney, are hardish areas and makes me think another tyre would be just as suitable. Wonder if TKCs fit XRs?? I rekon you would be a more normal tyre pressure then. Ive got to have a look at mine, but I prefer the dirty look for now. I guess with TKC it would highway cruise better also due to less rolling resistance.

Did do some reading here http://www.thumpertalk.com/forum/ and not sure about these Gordons mods plenty seem to say the header grinding makes no differance??? And I dont think I will bother drilling the spark arrrestor bit as its feckin noisy enough.

[YEN_POWELL]

I run my DR350 on 15psi front and back. That is without rimlocks on Pirelli MT21s. That's probably too hard for serious mud so I use the 'keep going at all costs' method of riding when in gloop.

[Kermit]

thanks for the tips on the pressures

Thurs 11th Sept
Tonight with the aid of my newly arrived stand I've gone from this when I got home tonight [it was more or less as I left it on Monday]

5.45pm


to this by 7.30pm


8.30pm


Boxes of parts






The only 'clean' box so far


The VIN Plate i need to remove and but also unknown to me till now there's a steering lock (no ignition barrel on these bikes) but I don't have the key so I think I'm going to have to grind that rivet off that hopefully will release it


I might well disassemble the complete engine, the top end or if I'm really lazy just do the valve clearances <- all subject to my time and patience


Next stop, a motor factor for some degreaser, then hopefully I can get it to the powdercoaters on Saturday morning for pickup the week after. Still haven't decided though wether to stick with the original white, red or maybe satin black?

[Kermit]

My Haynes manual turned up today...looking at their frame number it appears my 1996 XR is in fact a 1994 model...only had to alter one of my orders for parts as many parts are the same (apparently)

Anyone reading this?

Fri 12th Sept 2008

Man-sized can of gunk purchased - frame and a few other bits that should be going to the powder coaters tomorrow have now been degreased as per Triple-S recommendation

Have to get a dremmel grinder bit of my bro later and have a go at the VIN plate and lock. If as seems likely I go for Satin Black, I'll get the side stand done in the same colour. Might also ask how much to just sandblast/beadblast the exhaust system as while I can clean up most of it on the wirewheel, some of it is awkward to get at.




I've also given the swinger assembly a degrease to make further disassembly more pleasant


VIN Plate success
I had a look at the inner side in headstock tube and noticed a couple of pointy ends protruding a mm or so...turns out the vin plate is more or less pushed on tightly with pins and a bit of glue. Managed to prise the pins up a bit from the inside then lever the plate and pins from the plate side with a screwdriver - should be a doddle to refit



Steering Lock
Tried just grinding off the rivet bit but the lock still wouldn't budge so got the drills out and eventually after going up in size a good few times it was free

[catteeclan]

Keep going. Love these threads.

[shuriken]

I'm with cateeclan(hi mate), great thread. On my XR600 I'm running 30psi in tyres but this is road use on Metzler Saharas. Off road I'd look at 15 or 12 psi. Possibly use rim locks too as this will allow low pressures without the tyre moving on the rims.
Tyre wise I was looking at TKC's or going for road legal Enduro tyres but these will get chewed up farly quickly on the road due to the movement in the knobblies.