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Project Honda XL250s 1979

Discussion in 'Your 250cc Projects' started by Murdo, Jan 13, 2018.

  1. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    I bought this about six months ago but have only just got around to working on it. I bought from the original owner who had bought it in Sydney, NSW in 1979. It was registered for the first year but when he moved back to the family property at Coonabarabran, NSW he let the rego expire. It remained on the farm until he moved to Tamworth in 2016, when he advertised it for sale. We did a deal for the bike and some spares he had gathered over the years and I brought it home. It has had a few knocks and dents, some dodgy replacement bits and many years of dirt and sheep sh*t, but it only shows 4,400Km on the speedo which I believe to be true.
    phone photos 161.jpg phone photos 162.jpg
    Have replaced the handlebars (originals bent and cracked), washed years of crap off, lubed all cables, heated and straightened footpegs, bent sidestand back into correct position, etc. Have ordered new air filter, mirrors, tail light, bulbs, etc. The seat cover is original and the paint work and plastics not too bad. Has near new tyres and the chain and sprockets will go a bit longer yet. Engine runs sweet and will be getting an oil change, valves set, new plug and carb clean to make sure it is running it's best.
    The standard muffler had rusted out years ago and some 'farm welding' had been applied to it to stop it scaring the sheep, but it needed some attention to bring it up to the standard of the rest of the bike.
    Tammie visit -XL250s 008.jpg
    This is what it should look like.
    Tammie visit -XL250s 007.jpg
     
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  2. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Joined:
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    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    I bought a piece of 75mm exhaust tube from the local muffler shop. I measured the circumference at both ends of the original and marked onto the new pipe. I cut out the 'V' with my plasma cutter to get the right diameters.
    Tammie visit -XL250s 015.jpg
    Clamped back together and welded. I bough some fence caps from the big green hardware store and cut out the centres and flanges to give me the right looking end caps.
    Tammie visit -XL250s 017.jpg
    Then cut a piece of 1.6mm sheet to seal the front end, some 32mm tube for the first tube and some 25mm for the out tube. These I welded so that they overlap to make the sound/gasses change direction twice before they escape to atmosphere, and the front plate and end cap welded on too. The sizes I had worked out years ago with other bikes seem to work the best, so used the same here.
    Tammie visit -XL250s 018.jpg
    Welded together and smoothed off.
    Tammie visit -XL250s 019.jpg
    Here with a muffler from a 250R. Look much the same to me.
    Tammie visit -XL250s 020.jpg
     
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  3. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Joined:
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    Gender:
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    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    I cut the old bits off the bike and the fitting from the remains. Clamped into position and tacked. When happy with alignment I fully welded it all together. Some heatproof black paint and fitted the original heatshield.
    Tammie visit -XL250s 025.jpg Tammie visit -XL250s 026.jpg
    I think it will do.
     
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  4. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

    Messages:
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    Joined:
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    Gender:
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    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    Damn, just realised I've put the heatshield on backwards. Job for tomorrow.
     
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  5. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

    Messages:
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    Joined:
    May 4, 2013
    Gender:
    Male
    Occupation:
    Retired
    Location:
    Tamworth, NSW
    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, NX650, GN250, CJ250, CBR250, ZZR250 plus a few others.
    Got the heat shield on the right way. :oops:
    The tool box had lost its lid somewhere along the journey of the last 40 years and needed to make another one. I found a piece of 6mm plate close to the right size and traced a line from the end of the box.
    xxx 003.jpg
    Cut out with the plasma cutter and ground smooth with flap disc in grinder. Cut some 1.6mm aluminium sheet to about 6mm bigger than box and clamped to steel plate in vice. Worked the edges over with a planishing hammer to form the edges.
    xxx 006.jpg
    Cleaned up with a file and fitted nicely. I found some 1.2mm steel strip and made some hooks to hold a strip of tube rubber and riveted to sides of box.
    xxx 007.jpg
    Some black paint, stuffed the original tools in the bag in and fitted to bike.
    xxx 011.jpg
     
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