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Project A tale of two Yamaha xs250s.

Discussion in 'Your 250cc Projects' started by TonyB, Aug 7, 2025.

  1. TonyB

    TonyB Member Premium Member

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    My Bike:
    yamaha xs250
    3 weeks ago I ordered two xs250's and today they were finally delivered, some boxes of spares as well.

    [​IMG] [​IMG]


    [​IMG]
    [​IMG]

    The Black one has dodgy front brakes, so I need to strip them so it is easier to push.

    Slopped a new battery on her and all the lights work, the engine turns over but there is no spark at the plugs.

    Will see if I can get it to run tomorrow.

    I have stuck her in the shed for now, will strip it down for a resto later this year.

    The Green one has a soft front brake, loose silencers and has loads of tatt adorning it.

    Swapped the battery over from the other one and nothing, no lights or anything.

    Engine turns over on the kick start and has compression.

    After some cleaning of connectors I managed to get the lights working and a spark at the plugs, soo tank back on, plugs back in and fuel tap set to prime.

    Lots of kicks later, starter button is missing on the handlebars (but there are 3 spare switch cluster in the spares pile) she fired up. Need to put fresh fuel in the tank as it has not run for 7 years, but it runs. yaaaay.

    So the strip down and refurb can start on it.

    Tony.
     
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  2. TonyB

    TonyB Member Premium Member

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  3. TonyB

    TonyB Member Premium Member

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    Engine is out of the us custom frame.

    [​IMG]
     
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  4. TonyB

    TonyB Member Premium Member

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    [​IMG]
    Rear end is all stripped down.
     
  5. TonyB

    TonyB Member Premium Member

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    Frame stripped ready for cleaning.
    then rub down and a repaint.

    [​IMG]
     
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  6. TonyB

    TonyB Member Premium Member

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    [​IMG] [​IMG]
    Frame cleaned with petrol and gunk and then pressure washed.
    Wiped it down with brake cleaner and a cloth , got some welding to do in two places and then I can paint it.
    Tony.
     
  7. TonyB

    TonyB Member Premium Member

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    [​IMG]
    Frame painted.

    [​IMG]
    The task of cleaning/painting parts and then refitting has started.
     
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  8. TonyB

    TonyB Member Premium Member

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    [​IMG]
    Where we are today.
    Would like to lower the rear end a touch and I plan to do something with the seat to make it thinner and not so bulky.
     
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  9. TonyB

    TonyB Member Premium Member

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    Fiddling with the wiring at the moment.
    Fitted the air filters, side panels,tank,brake light switch.
    [​IMG]
    got some silencers on order, then I need to sort a seat and try to get it running again.
     
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  10. TonyB

    TonyB Member Premium Member

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    [​IMG]
    Got the silencers fitted.
    Filled her up with oil and got her running again.
    Not much different to what I started with, just tidied her all up and removed some questionable add ons the previous owner had fitted.
     
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  11. 2valve

    2valve Well-Known Member

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    Hi Tony.
    I do like the look of the Black XS , the stripes on the tank look's very cool.
    I'm not sure if you have found this site yet , but the seller list's some XS 250 part's , especially carby kit's , well , that's if there correct for your model.
    https://www.cruzinimage.net/?s=xs250
     
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  12. flea

    flea Well-Known Member Premium Member Contributing Member

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    87 cbx250 / 73 ..74..78 yam xs650 /zzr1100 / tdm850 /zxr250c / 250 across / 2008 canam spyder /xs250 / xs250 spyder
    now they look interesting , still have mine sitting in the container waiting , bought quite a few parts out of japan from cruzinimage and another mob {??? cant remember who) 400 conversion is not a bad idea even for a commuter 250 they are slow as a wet week
     
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  13. TonyB

    TonyB Member Premium Member

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    Well it looks like the engine has to come out again and have the head off.

    Only runs on one cylinder, got spark, got fuel, won't run on the left side.

    Vlaves are not stuck, so engine out, head off and we need to have a look inside.

    never mind.
     
  14. TonyB

    TonyB Member Premium Member

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    [​IMG]
    Engine out and the remains put into the studio.

    [​IMG]
    Head off and we have oil in the top of one cylinder.

    [​IMG]
    Barrel off and there is oil round the bottom.

    [​IMG]
    And the kicker, oil ontop of the piston.
    So new rings and gaskets needed I think.
    Will do the valve seals as well.

    [​IMG]
    The black one has fallen to pieces. playing with ideas at the mo.
     
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  15. TonyB

    TonyB Member Premium Member

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    well I have measured the bores in the 250 and they are 69mm, so it has a 400 top end.
    Piston rings for the 400 are oober expensive compared to the 250.
     
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  16. 2valve

    2valve Well-Known Member

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    That's pretty cool the top end being a 400 , a tad more HP , i wasn't aware that was possible.
    Had a XS 400 back in the day's , do what ever you can do to the top end on the rebuild , as there not a responsive bike as such and pretty heavy , no offence meant by that.
    Can you share the part number of the ring kit's your after , i'm curious as what the price's are over this side of the pond.
    Is the black XS that your going to do up ? , paint scheme / graphic's look's pretty good , O.E ?
     
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