Project Yamaha SRX 250 3WP

So... it turns out that the caliper mounts dont quite work for the FZR250 front brakes. Doesnt miss out by much, about 5mm on the OD and probably another 5mm width wise.. so Plan B is to use the SRX600 front and rear wheels...
They are 18" so a little more difficult to get tyres but there are Pirellis out there that are not too bad.
The original SRX250 had an 18" rear but was only a 100/90-18, so only 12mm difference in rolling diameter still leaves plenty of clearance.
I am able to get a rear sprocket that works to get me almost identical gearing and I will just need to sort out the rear brake mount... either weld a mount onto the swing arm for the torque rod or have an adapter made for the 3WP caliper mount.

I suppose that this way the bike will then be all SRX rather than an SRX FZR hybrid...lol.




Looking at that it might have been more like 10mm out in diameter...


Front guard would have needed to be lowered as well I think.

 

True.. the problem is that it sort of becomes a big jigsaw puzzle with modified pieces.
If I hadn't wanted it to look as though it was a "factory" 3WP model the FZR front end would have been fine and I could have used an aftermarket gauge cluster etc... but... as I wanted to use the 3WP gauge set and top bridge that meant with the 38mm forks that spacers would have been needed for the front wheel, discs or calipers and a much modified front guard as well as a modified headlight bracket and a way of modifying 36mm Factory bars to 38mm (the 38mm items are like rocking hose manure).
It may still happen that way yet... I will still rebuild the calipers as I have the kits already... and I will check on having the spacers etc made for the front wheel and new caps for the 38mm forks but at 36mm diameter for the bars.
I can most likely sell of the SRX600 bits seperately if I need to.. either way I have options so it isnt all bad.
If nothing else I scored a nice set of Goodrich braided lines for the front end.
I can also sell off the FZR parts along the way.. anyone looking for a nice set of wheels with highly polished lips...lol

 

Change in plans or back to the original plan with FZR wheels, forks, brakes as there were more mods required on the SRX600 bits than doing it this way.
Yamaha don’t make it easy with compatibility of parts across different bikes lol.

New bearings and seals into the back wheel, Cush rubbers back in and new rear disc.
Then slipped into the swing arm and a quick nip up and everything lines up.
A bit more mock up today and now it’s getting cold so time to quit.











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Picked up my Footrest Brackets today from the Powdercoater. They turned out a bit darker than I had originally thought based on other items he showed me but I do like them.
I think I might have to re-paint the front fork lowers to match though...he has given me the paint code so it should be a fairly good match.

The colour is Black Onyx Metallic.

 

It will look better once all the footpegs and brake lever are on... I have another set that I might just paint up in Wheel Rim Silver to see how they look vs the Black Onyx Metallic

 

Did some more today, I was hoping to try and get the tyres on but it is too cold and they are as hard as hell so I will probably take them down and get them fitted and balanced... Then it will be a roller... so progress I guess.
I started painting the bottom triple and rear footpegs in the Black Onyx Metallic and I think it will all look good when it is together.
I do have a rear sprocket in the Garage somewhere... just need to find it. I guess it is best to have that fitted for balancing.

Plus the seals that I ordered for the front wheel... one was incorrect so I need to get another one now...Grrrrrrrr

I am going to repaint the fork lowers tomorrow in the Black Onyx Metallic. I will let it dry for a few days and then Clear them next week and finally put oil in and the dust seals on... ticking lots of little things off as I can.

 

Well I finished off painting the fork lowers this morning and also started assembling the footrest brackets.
I didnt end up taking any pics as I needed to head out to Dubbo for work.
I think I wont post up any more pics until the bike is a roller next week and I can get it out in the sun

 

OK... I picked up my wheels from Western Motorcycles after having the tyres fitted and balanced.
Found my rear sprocket so I bolted that on and then installed the wheels into the frame and.............
Behold.... she is a Rolling frame. The seat isnt the right one (SRX51Y not 3WP) but the rake etc seems to be almost right, the rear shock is nice and firm.
A few things still to do before I take it off the lift so the CB400/4 can go up and be tickled and teased.

 

Things are still rolling along slowly with the SRX... I went and picked up my seat today... fully refurbished.. new hand cut foam, grey and black high quality Vinyl and it looks pretty good I think.

 

It has been a little while since I did anything on the SRX but today was a nice day and I managed to start painting up the 350 barrel and head in readiness for getting down to final engine assembly.

I even got the piston on. Unfortunately I ran out of engine paint so back to Repco in the morning lol.




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Managed to buy all the new SS Boots for the clutch cover and static cover today. I got done head capsrews so they look more like Factory but I can use the Allen key socket so I can torque them all correctly.
Over the weekend I will get the barrel on and then take a tip from @Murdo and use Plasticine to check I have proper clearance with these Factory high lift cams.
I have my machinist making some collars for the exhaust tube so I can start fabricating my SS exhaust.
Still lots to do but getting closer all the time.


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Got into it a bit more today... put in all my nice SS Dome head capscrews.. I like the way they look as opposed to normal capscrews.
I then assembled the top end with no Head gasket but with Plasticine on the piston... inlet and exhaust side and set the timing... turned her over a few times and then pulled it apart to check the clearance as shown on the Plasticine.
3.7mm clearance on Inlet and 4 on exhaust so with the head gasket she will be fine. The good thing is this piston is shown as 9.1 compression.
Tomorrow is final assembly day for the top end... plenty of oil in the bore and assembly lube on the cams etc... just to be sure.



Lots of lift at fully open....



Inlet is wide open here as well.

 

Top end is all assembled now. Just waiting on 1 gasket to seal her up and put some oil in.
I know I have the gasket here somewhere but I can find it in all the logical places so for $10 I ordered another one ( stator cover gasket )
There will be paint touch ups required but that is par for the course.
Now to get the cable routing sorted, oil line in and Carbys on.







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Hmmm it’s very tight with the vacuum line and the Oil line to the head.
Might need to bend it just a little to allow it to clear the oil connection.




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So I needed to get myself a new Clutch cable and figured while I was at it I would get some other bits and pieces rather than using the old ones..
I checked out Partzilla and everything including freight came to US$98... and then I checked on Impex.. now the clutch cable was US$8 more expensive than Partilla but... the total of all the bits.. plus freight came to US$68... in the end that is a saving in my pocket of close to A$50... it just goes to show it is worth shopping around.