Project Frankenbike! xr250 UPDATE - rebuilding

[waffles]

Ladies and gentlemen, I present to you Project Frankenbike!
https://i141.photobucket.com/albums/r71/siany_album/CIMG2705.jpg

I hurt my arm a couple of months back and the xr was left in the garage as I couldn’t ride, it hasn’t been started since then so my friend Tim has generously offered some workshop space and advice to fix up a few things that needed doing. The list keeps growing every time something else is removed! Taking off the plastics reveals that the air box isn’t really attached anywhere and the exhaust has a sizeable dent in it. The plastics on one side are Polisport, the ones on the other are Acerbis and none of the others are original. Odd, Tim recons the previous owner has pulled a wheelie and gone over the back of it. Other bits are hugely bodged into place (sealant holding a too-small bolt in place, other bolts hacked to make them fit, over use of cable ties....) so somewhere along the line it morphed from fixing a few things to making it work properly and look better. It is Frankenstein’s monster in two wheeled form.

At the moment I am working on the seat which did have a huge tear down the left hand side, was pretty faded and during emergency stops I can slide right up onto the tank. I found a grippy cover from RaceSpec and took to butchering the old seat! First the new seat cover gets chucked in the airing cupboard to warm through. This will make it stretchier and therefore easier to pull into place. I’ll probably iron it on a low setting to get out any crinkles and give a smooth finish.

I set out everything I needed because I am slightly OCD. Spray adhesive, staplegun, staples, knife, pliers and a screwdriver. At this point I took a bunch of pictures to show how the seat was put on especially round the corners for reference later.
https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2728.jpg
https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2735.jpg

As you can see, its had a tough life and been repaired rather badly. This section was just glued straight on to the seat foam. Better than duct tape I guess.....
https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2734.jpg

I used the screwdriver to lift up the staple and then pliers to pull them out. They were all rusted and some required lots of convincing to finally pull them free.
https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2737.jpg
https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2740.jpg

I was surprised at the condition of the seat foam underneath. I thought it would need some shaving down as it would have been going mouldy. Apart from the bad repair pulling some foam away it was very good.
https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2736.jpg
https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2741.jpg
https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2742.jpg

Some of the staples bit me
https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2743.jpg

So after a quick phone call to my mum to see when my last tetanus shot was I have the seat in bits, the original cover rolled and stored away safely and given the plastic part a rinse out in the bath. While that’s drying I am going to prep the new cover and foam.
____________________
Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[CaNsA]

[waffles]

Mums know best anyway

My stapler isnt butch enough to go through the plastic so I will carry on with this tomorrow.
____________________
Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[waffles]

The seat is currently on hold for the moment, I have a stapler that will now go through the plastic but the cover I bought doesn’t fit properly. So im going to return that and get a different one.

At the start of the day the bike looked like this.

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2745.jpg

After putting the world to rights, the first thing to sort was the exhaust which was caked in mud. The heat shield is going to get sand blasted and painted up, I took off the silencer and header pipes which will be polished up with a mixture of green scrubbers, WD40 and some emery cloth later. They will look pretty sweet when done.

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2746.jpg

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2747.jpg

The old broken air box had to come out and pulled apart to get some bits ready to go on the replacement one. Some of the bolts needed persuading (I wanted to yell at them, I was convinced that a long bar works better!) and the back end was gently pulled out.

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2749.jpg

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2750.jpg

Off came the carb....

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2751.jpg

I got dirty hands

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2752.jpg

The heavens opened so after quickly throwing a cover over the bike I decided to have a go at the exhaust headers.

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2753.jpg

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2754.jpg

The carb was pretty easy to take apart but filled with bits of dirt, float adjustment was the first task then I cleaned out the jets. I have ordered a carb filter which hasn’t arrived yet so I packed all the bits away neatly ready to be reassembled at a later date.

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2755.jpg

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2756.jpg

Tomorrows job is to take apart the old and replacement air boxes and turn the bits into one working one.

Things that still need doing:
Order new seat cover, side panels, air valve guards, possibly gear lever
Clean out mud from the front forks
Rebuild and set up the carb
Work out why its burning oil
Polish exhaust
Mount the numberplate on the fender
Sandblast and paint the heat shield
Fix the steering lock
General clean up
____________________
Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[Bike Bunker]

following, no not like twitter

[Tim..]

Thats how my hands look after they've been washed.

keep it up, going well so far
____________________
Project builds: My VFR400 nc30 build thread + Honda Britain Rep VFR + What? Another VFR +Project 'cos I want one' + V8 coffee table
www.marshallracing.co.uk
OCD - Helping to bring the standard of my bikes up and make me slowly go mad since 1999

[waffles]

Cheers guys!

I hate dirt behind my fingernails but im slowly getting used to it! I went a bit mad with the credit card last night and ordered a bunch of bits. Stripping back the air boxes just now revealed more mismatched bolts, one was even wrapped in what looked like electrical tape

More importantly theres a crack in the frame so I guess I need to learn how to weld....
____________________
Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[waffles]

The bodgetastic nature of this bike is showing and starting to get very annoying, nothing seems to be a straightforward job anymore. I started the day by trying to turn these bits into one working back end.

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2757.jpg

The back of the numberplate shows that its burning way too much oil, I wiped this down not too long ago and its done around 100 miles since then.

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2758.jpg

Taking a closer look at the frame and I found yet more evidence that the bike has gone over backwards, a crack in the frame. Hurrah! Still the subframe has lots of rust patches so it needs some TLC anyway.

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2760.jpg

The obsessive compulsive part of me took over and I bagged up all the goodies that I can reuse from the old and new air boxes. Everything is going to get a good clean in WD40 to get all the grease and muck off so it looks fairly shiny.

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2761.jpg

Subframe got a quick clean and dry

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2762.jpg

Frankenbike strikes again! To make it look nice and sparkly some twonk spray painted the frame but stopped where the frame guards were so now I have a fetching two-tone bike.

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2763.jpg

Then onto the task of loosening off some bolts, the swingarm bolt in particular looked rusty and could be a problem. Turns out it was. Both sides had been rounded off and needed a mallet and some grunt to get them off; I was putting so much pressure on the ratchet that the back wheel slowly touched the ground. Eventually it popped, loosened off then tightened up again. Turns out it was properly shagged!

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2764.jpg

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2765.jpg

Thats all for today

Is Hammerite the best thing for the rusty parts of the frame? After removing the old paint do I just paint on the Hammerite or does it need a primer or base coat of anything?
____________________
Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[Tim..]

where abouts are you? I work in Gillingham
How big is the subframe? I'll bead blast the subframe back to bare metal for a small amount of cash.

Could ask one of the lads in the workshop to weld it up too.
____________________
Project builds: My VFR400 nc30 build thread + Honda Britain Rep VFR + What? Another VFR +Project 'cos I want one' + V8 coffee table
www.marshallracing.co.uk
OCD - Helping to bring the standard of my bikes up and make me slowly go mad since 1999

[Moo.]

Yeah Hammerite is straight to rust applied, no primer or base coat. Just slap it on there
____________________
A2 Passed 18/6/10

[waffles]

The ex's dad has offered to weld up the crack but I will take you up of the offer of bead blasting it, Tim. Its not especially huge actually and weighs next to nothing. I'll pass over some beer tokens for your time etc I'll send you a pm as soon as I get it back.

Just slap the hammerite on? I approve!

I now have one working and fully de-manked air box and the exhaust is starting to come up nicely with some elbow grease
____________________
Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[Tim..]

Ok no probs.

I asked about the size to make sure it'll fit in the bead blasting box.

I got my vfr nc30 subframe in there so it should be ok.
____________________
Project builds: My VFR400 nc30 build thread + Honda Britain Rep VFR + What? Another VFR +Project 'cos I want one' + V8 coffee table
www.marshallracing.co.uk
OCD - Helping to bring the standard of my bikes up and make me slowly go mad since 1999

[waffles]

I'll measure it up when I get it back, its narrow but fairly long. Maybe 50cm from end to end?
____________________
Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[P.]

[waffles]

Course you can have a go when its all put back together, Paddy If you can cope with how amazing its going to be.....
____________________
Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[P.]

[waffles]

Deal! Ive been wanting to learn how to wheelie for a while
____________________
Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[waffles]

Anyone know anything about wheel spokes? A few in my front wheel are actually bent and lots more need tightening. Is that an easy job to do myself or best taken to someone who knows what they are doing?
____________________
Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[P.]

[waffles]

The Postie brought some presents!

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2766.jpg
____________________
Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[HoggyF]

Re your spokes

I ordered some replacement spokes for my old Xt and fitted them myself, was easy enough to do and if you don't go daft tightening them up it should stay true (assuming it's true at present) When I tightened mine up I kept "pinging" the spokes with a screwdriver until they all sound the same sharp ringing sound. If you need to tighten any of the others soak them in WD40 or similar for days coz they snap easily.

Check both wheels and tighten up any loose ones before ordering any new ones as you might find you need more that what you think after you snap a few

Theres a few places that do spokes, Hagon, Roy Thursby, etc just look in MCN, some might not have patterns for your spokes straight off so you sometimes have to send one as a pattern but i just kept ringing round till i found someone who had them (can't remember who now though - old age!!)

[waffles]

Cheers HoggyF, it sounds fairly straight forward so I'll give it a go myself. The wheels have to come off anyway as the inner tube valve has been shoved out of the rimlock gap and I have my blingy red bits to replace them with

The clocks have been trashed and "repaired" so eventually they will be replaced. I would love a digital dash but we'll have to see what the budget allows.

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2769.jpg

These are the clips that came out of the fork legs. I think it was a good idea to pick out the rusted remains and replace with shiny new ones! The previous owner apparently doesn't know what a tub of grease looks like or how to use it. The gave both forks a good clean and picked out the solid mud that was trapped up in the gaitor. They are starting to perish so if the forks end up being removed I will source a new set.
.
https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2768.jpg

And this is how he looks now!

https://i141.photobucket.com/albums/r71/siany_album/Fixin%20the%20XR/CIMG2767.jpg

The spindle is properly seized in place and won't budge despite the best convincing with a hammer and some choice words. I fear it may have to be introduced to Mr Hacksaw or one of his associates. On the plus side, the steering lock barrel is off and im going to try to get a new set of keys cut for it.

Onwards!
____________________
Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[mrtEE]

[waffles]

[mrtEE]

What I mean, is that maybe the front axle is not budging as you need to loose the front axle pinch bolts first.

At the bottom of the fork legs, there are 4 bolts which "pinch" the axle tight.