1977 XL250K4 -- nao wid vid innit

pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

While my CB is coming along slowly there are a lot of bits that are going to take time to sort out properly. Not to mention replacement parts that I'm going to have to wait to turn up...

So, I decided to dig this XL out of the shed as it's not a massive challenge to get this one back on the road.

Here's how it was about 3 years ago...

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/bikeside.jpg

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/bikerearright.jpg

Later that day it looked like this

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/bikeminimal.jpg

Then I took it apart some more, put all the bits in various boxes and put it away thinking "I'll get that done soon."

About 3 years later and it's today. The only thing I did to it in the meantime is fit some different tyres to check clearances (which I never actually did).

So now I've got all the bits in one place (not piece) again - I put the rear wheel into the swingarm to see how that tyre fits.

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/PICT0712.jpg

And fit it does Laughing

Now all I have to do is get on with the rest of it...

TheSmiler · World Chat Champion Joined: 14 Apr 2011 Karma :

MOAR PHOTOS
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pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

Bit more done...

The plan is to build the bike up completely so I can fix stuff (frame needs a little tickle here and there) and see exactly what I need to get/do, then tear it back down for paint etc.

So, swingarm and wheel in:

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/PICT0714.jpg

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/PICT0713.jpg

Yes, that is a bit of wood instead of a rear shock, I've got the shocks in bits to clean up...

Then the yokes:

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/PICT0716.jpg

And forks, front wheel etc:

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/PICT0717.jpg

Now I've created a problem for myself - the handlebars are too wide to fit through the door! I think I'll stick a narrower set on while I'm messing for now, at least I'll be able to move it easier then.

At least it's now rolling Very Happy

KLR600 · World Chat Champion Joined: 15 Mar 2005 Karma :

Looking forward to seeing this done! Hope it doesn't take another 3 years to get to that point though Wink

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.Chris. · World Chat Champion Joined: 09 Jun 2007 Karma :

Very nice indeed Very Happy

. Just a shame bikes like that now seem to cost quite a bit.
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Chris
1985 Kawasaki Z550F

Pol Anorl · Banned Joined: 13 Apr 2010 Karma :

looking good, get that frame blasted and repainted job jobbed, progress is looking slow but its progress keep it up.
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pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

KLR600 · World Chat Champion Joined: 15 Mar 2005 Karma :

Don't Hagon make custom length shocks for not a ridiculous amount of money? I imagine it would be pretty easy to find the original eye to eye shock length and see if they can make you a pair up. Might be easier than fabricating mounts but then if you've already made them I guess it doesn't matter!
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Teflon-Mike · tl;dr Joined: 01 Jun 2010 Karma :

pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

Hagon do a set of 'off-the-shelf' trail shocks for this model for £160 - not far from what I paid for the actual bike. I could alternatively get a set of budget shocks for ~£50 on ebay.

On the other hand though - I could cut up a scrap swingarm I had in the shed, weld the mounts on to the original arm in such a position as to allow me to use a much more common length of shock while lifting the back of the bike by around 10mm and only losing about 20-30mm of actual travel (depending on make of shock) and use a set I already have for £free. This would also mean that when I need to replace them I have a much wider range to choose from.

So I did.......

I know it's not 'original' but that's not the aim with this one. It's a build not a restoration after all. If I was going for a restoration I would make sure I had a larger budget than £0.

Anyway, it still runs! So that's good. A bit more to do on the frame reinstating what was cut by a previous owner and it'll be getting taken apart again for paint.

Teflon-Mike · tl;dr Joined: 01 Jun 2010 Karma :

KLR600 · World Chat Champion Joined: 15 Mar 2005 Karma :

pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

.Chris. · World Chat Champion Joined: 09 Jun 2007 Karma :

pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

More on the shocking saga...

I cleaned up the ones I had a bit and as it turns out they are a bit worse than I first thought.

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/oldshock.jpg

So, time for a newish plan. I got these.

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/newshock.jpg

Which I could do this to:

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/internals.jpg

Right, so I have springs that I can fit to these but there is the continuing problem of length - but for this I have a cunning plan..........

pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

So, the plan.

I had one set of slightly knackered shocks that were too short anyway, and one set of serviceable shocks that were also too short. What to do......

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/cutshocks.jpg

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/shockbottoms.jpg

That.

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/mockupshocks.jpg

Look at that, they're longer Laughing

Now to stick them together.

ocatoro · World Chat Champion Joined: 06 Sep 2012 Karma :

really like that. look forward to seeing more of it Smile

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pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

Got the shock bodies welded up:

https://i834.photobucket.com/albums/zz267/pdg555/bike/XL250K/shockbody.jpg

Got about an extra 35mm on there now, I might also change the top rings to match the new bottoms.

And a few other little bits that aren't photo worthy...

One of the next bits is to make the fuel tank a bit more unleaky.

Nearly ready to strip it all back down for paint etc.

Fizzer Thou · World Chat Champion Joined: 06 Aug 2011 Karma :

My brother used to have one of those bikes.Lots of stories involved with that ownership Laughing

https://i666.photobucket.com/albums/vv23/WiNot_Rhencullen/Snaps/HondaXLBikes001.jpg

Page from the Honda sales brochure of the time
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pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

Bit of a un-update this one really. The project is far from dead but I got a bit distracted with lots of other things...

I have got a bit more done, but nothing I consider photo-worthy yet. Some little bits left to do and once my compressor is finished this will be getting blasted and painted.

That brochure page is cool by the way, I think it's of the same model but mine has no rev counter (or space for one) - what it does have is markings on the speedo to indicate when to change gear Laughing

pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

As anyone who knows me will attest, I can't be doing with all this rushing malarkey.

Now, I don't know how many people have painted bike stuff before, but those who have will now that it's important to let the paint cure properly before doing anything else with it.

So.....

Last July (2013) I found a petrol tank off of something else which looks like I want it to and was made to fit quite easily.

Then I painted it, and put it indoors to cure.

Over a year should be enough time to let paint dry shouldn't it?
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pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

Crappy video ahoy!
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Any and all advice given should not be followed - if you have to ask it means you don't know so get a man in to do it for you.

pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

Ok, so that petrol tank I got last year was a 'hongdou' one...

I made a couple of slight repairs, pressure tested it then painted it.

fast forward nearly a year, put some petrol in it and

it bloody leaks from somewhere I didn't repair that went through pressure test just fine.

Arsebuckets.

Ho hum, another tank has been sourced....
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Any and all advice given should not be followed - if you have to ask it means you don't know so get a man in to do it for you.