SR250 New Zealand Garage Build

vphillipson

New Member
Hi Everybody, thought I would put up some photos of my Yamaha SR250, which I got late last year.
Originally bought t with the intention of just tidying up and riding around but soon enough it was in pieces and decided it was going to be the winter project. Started out by skimming down the seat to get rid of the ugly stepped seat and recovered it,also put some drag bars on to lower the front of the bike. Havn't really set out on a style but took some inspiration from various bikes. Gave a time-frame of about 6 months to get it done, so ill put up some photos of the process as its all finished now.
Its my first foray into motorbikes so I appreciate any feedback comments/criticisms(maybe) ha Cheers!
 

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Re: SR250 Build

Didn't want to make any structural changes to the frame just yet, just wanted to see how the stock seat could be made to look a bit better, bought some upholstery foam, reshaped the original foam and sewed up a new cover for it, quite basic but changed the look of it a lot.
 

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Re: SR250 Build

Stripped the bike down, also marked the frame tags, etc that would need to be cut off before i colud start mocking up the
seat and tank placement
 

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Re: SR250 Build

Cut the tail posts off, had a tail loop bent up then had it welded on, wanted the edge of the frame to be visible underneath the seat.Now its was rolling I could start to get an eye for how the frame/tank/seat would sit,
also lowered the tank mounts on the frame to drop it down at the front a bit. Also serviced the forks with new seals oil seals etc. Also painted the triple tree upper while it was off with new bolts as well, the rear shocks are off a triumph which I got for a bargain. Brackets are for the rear mudguard.
 

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Re: SR250 Build

The rear guard was a left over fiberglass trailer guard that I cut the general shape out of, left in some tags to fit the rear indicators to but decided to change their position later on, also fitted it up to check how the rear tail light would fit.
Also didn't want to keep the large front chrome guard so we welded up a new fork brace and cut a small front fender to bolt on.
 

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Re: SR250 Build

Now the tail loop is on, I had ago at a fiberglass seat pan. Put down tin-foil, and made the tank mount hump by molding playdough around it. First experience with fiberglass happy that it turned out ok. At the same time put some reinforcing strips of alloy in the layers and glassed in a few mounting bolts.
 

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Re: SR250 Build

Looking very good mate, I've getting near finishing my SR250, you can check it out here: http://www.dotheton.com/forum/index.php?topic=38765.0
 
Re: SR250 Build

Just getting done building one of those as well. the frame isnt setup for a cafe like the dt250 is. Its more of a bobber stlye frame. So mine is becoming more of a flattracker bobber type. fun lil bikes tho. Good luck
 
Re: SR250 Build

I think they are a god platform to work from, cheap, reliable, easy to work on, all the best for yours
 
Re: SR250 Build

Frame and swingarm, triple tree, kickstand and bits are all stripped of paint ready for powdercoat. Knocked the swingarm bushed out with a large punch, amazingly they came out quite easily. Knocked out the headset races before paint as well. Had the frame soda blasted, there was a lot of surface rust still to remove after though.
 

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Re: SR250 Build

Back from powdercoat, it came up really nice. Its a charcoal grey sparkle, seems to change colour depending on the light which is cool. Fitted the rear shocks, have had the headest locknuts etc rechromed and zinced. Thetool on the floor in the second picture is a bicycle headsetpress which I borrowed from work, worked perfectly on this as well!
 

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Re: SR250 Build

Heres a closer look at the tank mount which has been moved down about an inch
 

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Re: SR250 Build

Next up was the engine, it still ran really well so I decided to just give it a tidy up, paint and polish, then maybe pull it to bits next winter if ive still got the bike. Cleaned up the fins and case with drill mounted wire brush, painted the head with a high temp vht spray, and kept the case silver, polished all the sidecovers by going through the wet and dry grits then s spinning polisher on the drill. Fitted new gaskets on the sidecovers as the old ones were toast. New screws for all the covers as well.
 

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Re: SR250 Build

Shes back in the frame and its starting to look like a bike again! Picked up a set of pro taper bars through work, similar to the renthal ultra low shape. Bent the levers back into shape, also polished them, painted the lever body, with the barrell adjusters re zinced. Tried mounting the indicators underneath the brake levers but kinda went of the idea after a while, ended up making a bracket and fitting them to the forks. Mounted the horn under the tank but moved that later on as well. Also picked up a new ignition as the old one was pretty beaten up. New fork Gaiters also. Next up is the wheels.
 

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Re: SR250 Build

The wheels were in pretty good nick, the rim chrome was great so I decided to leave it, the black rims look sweet but the chrome seemed to go well with the frame colour, I had the spokes and nipples re zinced, and painted the hubs the same colour as the engine head.
 

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Re: SR250 Build

Had the brake arms re-plated. I re laced and rebuilt the wheels myself using the rear swingarm and front forks as a truing stand. Have built a few hundred bicycle wheels so these use much the same principal just on a larger scale!
 

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Re: SR250 Build

Thought a long time about what tyres to fit, wanting to keep the cost down I kept the front one but decided to get a bigger rear to fill out the back of the bike better, the original one looked a bit puny on it. Came across the white wall style, kinda took a punt on it and as the bike came together it started to fit in with the scheme.
 

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Re: SR250 Build

Had the carb cleaned up by using glass bead blasting, it came up really well, fitted the pod for it also, polished the bowl.
 

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