XR250 Project

[at106]

I bought this bike off of a forum member as it was cheap (ish) although i dont really have the space for another bike So once it's running i plan to either sell it, or keep it and sell my dr350.

I was told by the previous owner that it basically needed a top end rebuild, however upon arrival it looked a lot better than i first thought. It arrived to me with the piston and cam chain removed and the engine loosely bolted together so i quickly stripped it back down.

https://i448.photobucket.com/albums/qq202/at106/027-1_zpsc6c9efaa.jpg
https://i448.photobucket.com/albums/qq202/at106/028_zps23450545.jpg
https://i448.photobucket.com/albums/qq202/at106/029-1_zps6ece4cee.jpg
https://i448.photobucket.com/albums/qq202/at106/032_zps85db7ff5.jpg

It needs a good clean but already im starting to like it due to it's simplicity.

https://i448.photobucket.com/albums/qq202/at106/035-1_zps982831ee.jpg
https://i448.photobucket.com/albums/qq202/at106/036-1_zps4fdd81d6.jpg
https://i448.photobucket.com/albums/qq202/at106/033-1_zps2754b409.jpg

I then removed the cylinder head and the cylinder and all looked good. I was expecting the piston and cylinder to be scored (as i was told it needed a new piston) but luckily it was all ok. I measured the bore, piston and piston ring end gaps and decided it just needed a new set of rings.

The piston is a 77mm wiseco piston taking the engine upto 266cc.

https://i448.photobucket.com/albums/qq202/at106/023-2_zpsbedd00da.jpg
https://i448.photobucket.com/albums/qq202/at106/024-2_zps29451f2b.jpg

The reason the cam chain was removed is because it needs replacing, as you can see in these pictures it's eat away at the tunnel!

https://i448.photobucket.com/albums/qq202/at106/041-1_zps7b5f801b.jpg
https://i448.photobucket.com/albums/qq202/at106/039-1_zps9f87b8d3.jpg

But that can be easily fixed. The only issue i've found so far is that the inlet valves are very worn although i've read that it's very common. So i'll probably be replacing them with a set of wiseco steel valves. That's all for now until parts turn up

[Fizzer Thou]

Looks good.Do not forget to hone the bore lightly before installing new piston rings.I helped a friend with a similar engine project in the early part of last year (2012).

https://www.bikechatforums.com/viewtopic.php?t=234319&highlight=xr250
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Just talk bikes.What else is there?

Always have a 'Plan B'

[at106]

[at106]

Last week the remaining parts arrived so i could get the engine back together.

https://i448.photobucket.com/albums/qq202/at106/Picture840_zpseba37a50.jpg

The bore was honed and the piston and rings fitted, i also removed the clutch so the new cam chain could be fitted.

https://i448.photobucket.com/albums/qq202/at106/Picture830_zps18dd5066.jpg
https://i448.photobucket.com/albums/qq202/at106/Picture828_zps1f37e879.jpg

I decided the intake valves weren't as bad as i first thought so they're staying for now. After lapping them in they looked a lot better.

https://i448.photobucket.com/albums/qq202/at106/Picture836_zps1b440859.jpg
https://i448.photobucket.com/albums/qq202/at106/Picture835_zpsa5703288.jpg
https://i448.photobucket.com/albums/qq202/at106/Picture841_zpsb83ea2fd.jpg

Next i fitted the cam chain, camshaft, cylinder head cover and set the valve clearances however i forgot to take pictures

I changed the oil filter and filled it up with oil and it started after a few kicks, however there was a serious oil leak from the clutch cover gasket.

https://i448.photobucket.com/albums/qq202/at106/Picture843_zps2919cdd4.jpg
https://i448.photobucket.com/albums/qq202/at106/Picture844_zps3e294e4b.jpg

A new gasket sorted that and now it's been running perfectly for the last 100km and i think im going to keep it I'll get some more pictures next time i take it out.

[waffles]

I have a soft spot for xr's, its good to see another one fixed up
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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

[thx1138]

cool glad you fixed it up, hope you make some money, or enjoy riding it, either way rather it was still on the road than at a breakers yard. Pick up my new Honda on Saturday.

p.s better change my avatar now