DO THE TON

Blood Sweat Tears and Grease => Projects => Trackers => Topic started by: vortexracing on Dec 15, 2014, 17:38:24

Title: Yet another SR250 Tracker UK Build
Post by: vortexracing on Dec 15, 2014, 17:38:24
Well I picked this little thing up for £300 with a full years MOT and 6 months tax.


(https://farm8.staticflickr.com/7012/13666865265_5397d85703.jpg) (https://flic.kr/p/mPGfU2)Untitled (https://flic.kr/p/mPGfU2) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr


was a bit oily, looked like it had never been cleaned

(https://farm4.staticflickr.com/3906/14422966391_3e5738dbd7.jpg) (https://flic.kr/p/nYvtqk)P1050488 (https://flic.kr/p/nYvtqk) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

My biggest concern was this exhaust stud was loose, looks like a heli-coil is called for and a new stud.

(https://farm3.staticflickr.com/2936/14446490033_b6d0d6e174.jpg) (https://flic.kr/p/o1A3bn)P1050492 (https://flic.kr/p/o1A3bn) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

Stripped it down so far to this and started to try and clean the years worth of chain lube off the rear wheel.

(https://farm4.staticflickr.com/3845/14422950851_9537f892a5.jpg) (https://flic.kr/p/nYvoNp)P1050497 (https://flic.kr/p/nYvoNp) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

Got the inspiration form the Autofabrica SR250 and the Orange 'Mexico' one off here that SteveG posted.

Hopefully it will turn out similar to those.











Title: Re: Yet another SR250 Tracker UK Build
Post by: pigp3n on Dec 17, 2014, 21:56:03
cool post up lots of pics especially your take on how to change the seat.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Dec 28, 2014, 15:31:15
Wiring loom removed, and next the motor.

(https://farm8.staticflickr.com/7560/16129980515_e23fbaef39.jpg) (https://flic.kr/p/qzmnfk)20141226_202233 (https://flic.kr/p/qzmnfk) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

Whoever had the bike before me must have never cleaned around the front sprocket area, it's got 1/2 inch thick of oil and chain lube on it.

(https://farm8.staticflickr.com/7473/16129819405_78a6596fdd.jpg) (https://flic.kr/p/qzkxmz)20141226_204845 (https://flic.kr/p/qzkxmz) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr


While I'm posting on here, how easy/difficult is it to reduce the fork length/travel. If I go with std fitting bars rather than clip-ons, I can only drop the forks by about an inch, before they interfere with the handlebars.

I may just be able to get the tank and fwd portion of the seat on an horizontal level, but I may have to resort to lowering the forks. The other option is to drop them a lot further in the clamps and fit clip-ons.

advice on the fork lowering would be much appreciated.

Ta

Dave 
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Feb 20, 2015, 15:24:07
I'm after a bit of help please?


Just come back from the workshop who will be aquablasting the cyclinder head and barrel and he says it will be much better if I can remove the valves, cam and followers.


I can see that the follower pins are installed from one end only, and have a threaded (M6) hole in them, but can some body tell me the best way the remove them so I can get the followers out of the head please?

Thanks in advance

Dave
Title: Re: Yet another SR250 Tracker UK Build
Post by: cosworth on Feb 21, 2015, 23:26:04
The forks are easily lowered. Pm me.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Feb 22, 2015, 05:42:44
PM'd   :)

Ta
Title: Re: Yet another SR250 Tracker UK Build
Post by: hillsy on Feb 22, 2015, 07:39:56
I'm after a bit of help please?


Just come back from the workshop who will be aquablasting the cyclinder head and barrel and he says it will be much better if I can remove the valves, cam and followers.


I can see that the follower pins are installed from one end only, and have a threaded (M6) hole in them, but can some body tell me the best way the remove them so I can get the followers out of the head please?

Thanks in advance

Dave






You need to use a slide hammer to remove them. M6 bolts in the pins and "knock" them out with the slide hammer.
Title: Re: Yet another SR250 Tracker UK Build
Post by: zap2504 on Feb 22, 2015, 13:04:56
I may just be able to get the tank and fwd portion of the seat on an horizontal level, but I may have to resort to lowering the forks. The other option is to drop them a lot further in the clamps and fit clip-ons.
What I've done with mine (so far) is to use 13" shocks (originally for an XS650) and a spacer block to raise the rear of the tank so it is horizontal. The seat I'm currently working with (a XR tracker knock-off) will then be mounted horizontally with the tank. I did not want to make any permanent changes in case a future owner wanted to restore it back, so I did not change the front forks nor did I want to reduce front suspension travel - but depending on what I see I might raise them slightly in the triples.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Feb 22, 2015, 13:12:07
Sorted !!!

Thanks , had a good think over a couple of beers last night, and decided to have a go at making a pulley. I don't have a small slide hammer.

3mm thick steel strip with a 6mm hole in it and 4 different lengths of 6mm bolts and they both came out easily in the end.   :)

Didn't even need to heat them up 

(https://farm9.staticflickr.com/8678/15993788653_a37b9b357c.jpg) (https://flic.kr/p/qnjm9M)20150222_163029 (https://flic.kr/p/qnjm9M) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

My next thought was about the cam  ???

But a quick pull and wiggle and the whole lot came out. It only left the roller bearing in the far end.

(https://farm9.staticflickr.com/8566/16427950409_aafa028b1d.jpg) (https://flic.kr/p/r2Fxji)20150222_165013 (https://flic.kr/p/r2Fxji) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

I'll pop into the aquablasters this week and see if he thinks that will be OK left in, I don't fancy trying to get that out   :o

I suppose I could always try and mask it in some way, just to keep the abrasive stuff out as much as possible.

Has anybody removed that inset bearing and re-fitted one, if so how did you do it.?

Anyway, all out and ready to go except that bearing and I need to find somebody with a small spring compressor then the Valves can come out.

(https://farm9.staticflickr.com/8653/16406465327_f2e2cf6803.jpg) (https://flic.kr/p/qZMqxR)20150222_165033 (https://flic.kr/p/qZMqxR) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

Here is the offending stud that needs a clean and re-weld, then tapping, the previous owner must have known it was blowing, the whole area is black around the exhaust port.

(https://farm9.staticflickr.com/8582/16613141472_6693c0abe2.jpg) (https://flic.kr/p/rj3GaE)20150222_164940 (https://flic.kr/p/rj3GaE) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

Head and Piston/barrel  look good, the motor looks like it's in really good condition, apart from that stud.    ::)

(https://farm9.staticflickr.com/8584/15994006583_093a8a84ce.jpg) (https://flic.kr/p/qnksWc)20150222_164946 (https://flic.kr/p/qnksWc) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8660/16406465197_634f533f4e.jpg) (https://flic.kr/p/qZMqvB)20150222_165001 (https://flic.kr/p/qZMqvB) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr


Lastly, I'm assuming those pivot pins will need new o rings? am I correct?


Thanks for your help , it's really appreciated. 

Quote
What I've done with mine (so far) is to use 13" shocks (originally for an XS650) and a spacer block to raise the rear of the tank so it is horizontal. The seat I'm currently working with (a XR tracker knock-off) will then be mounted horizontally with the tank. I did not want to make any permanent changes in case a future owner wanted to restore it back, so I did not change the front forks nor did I want to reduce front suspension travel - but depending on what I see I might raise them slightly in the triples.

I'm looking to lower the front mounts on the frame as well as maybe lift the rear of the tank. Re-sale is not on my agenda at all.


Cheers

Dave
Title: Re: Yet another SR250 Tracker UK Build
Post by: zap2504 on Feb 22, 2015, 13:36:24
I'm looking to lower the front mounts on the frame as well as maybe lift the rear of the tank. Re-sale is not on my agenda at all.
Understood - but if you are doing a "tracker" (as opposed to a "cafe racer") you would want to work toward a more upright seating position (e.g., higher/flatter handlebars - I'm planning on using ones from a KLR650; higher/flatter seat) with as much suspension travel (for rougher roads) as possible. Lowering the front suspension and using clip-ons will reduce suspension travel and create a more "crouched" riding position.
Title: Re: Yet another SR250 Tracker UK Build
Post by: cosworth on Feb 22, 2015, 14:07:08
I think even a tracker needs the front end quickened from the stock cruiser, soft as butter front end. 
Title: Re: Yet another SR250 Tracker UK Build
Post by: zap2504 on Feb 22, 2015, 14:41:04
I think even a tracker needs the front end quickened from the stock cruiser, soft as butter front end.
I tend to agree, but would prefer (again, for a "tracker") to use the previously-suggested CB/CL360 or CB400F front springs and slightly heavier fork oil VS reducing fork travel.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Feb 22, 2015, 14:52:11
Quote
Understood - but if you are doing a "tracker" (as opposed to a "cafe racer") you would want to work toward a more upright seating position (e.g., higher/flatter handlebars - I'm planning on using ones from a KLR650; higher/flatter seat) with as much suspension travel (for rougher roads) as possible. Lowering the front suspension and using clip-ons will reduce suspension travel and create a more "crouched" riding position.

I understand what you are saying, the truth is I may be leaning towards a café racer after all, people do a lot of SR's as trackers, I may venture into the other café style. I may be asking the mods to move the thread to the café listings  ::)


I have to agree with cosworth, regardless of style the forks either need dropping in the clamps or better still shortening.

Thanks for the advice on shortening them cosworth, I'll have a go at it.

I may be back for more advice if I do   :-[

Wheels
Tyres off the rims yesterday, I had always wanted to have black rims and hubs with stainless spokes, but the cost seems way to prohibitive at the moment (circ £500!!!)

So after discussions with the guys at fastline parts in Leyland, England he suggested aquablasting the spokes and giving them a clear coat of lacquer. It may not win any concourse events but will look OK. The outside of the chrome rim is in great condition, the insides however require some cleaning up   ::)

(https://farm9.staticflickr.com/8661/16614916495_67399e0c90.jpg) (https://flic.kr/p/rjcMPv)20150222_184153 (https://flic.kr/p/rjcMPv) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8634/16613779681_71c76bcf39.jpg) (https://flic.kr/p/rj6XTg)20150222_184159 (https://flic.kr/p/rj6XTg) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8643/16588950316_11639e5b6f.jpg) (https://flic.kr/p/rgUGYL)20150222_184232 (https://flic.kr/p/rgUGYL) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8566/16614270472_2e5e473deb.jpg) (https://flic.kr/p/rj9tMb)20150222_184208 (https://flic.kr/p/rj9tMb) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8667/16407612217_76c6a18eaa.jpg) (https://flic.kr/p/qZTitP)20150222_184216 (https://flic.kr/p/qZTitP) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr



Ta

Dave


Title: Re: Yet another SR250 Tracker UK Build
Post by: cosworth on Feb 22, 2015, 21:19:04
With my spacer to lower the forks I can barely compress the springs to get the cap back in. Plenty of resistance on these forks now.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Feb 27, 2015, 14:53:46
Just dropped my head, barrel and crankcase covers off at fastline parts in Leyland in the UK.

Graham the owner and the most enthusiastic guy I have met in a long time  :)

Posted a before and after on FB

Before

(https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10986439_677664482343085_6562594222723814339_n.jpg?oh=a7dfdd3f237a7ebfb776bc875d753425&oe=5595DA64&__gda__=1434778894_c5a9f22cedacf2e554b2808078bc87b3)



After

(https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/10364214_677664505676416_1294694488357849922_n.jpg?oh=68737d3fdb409a9309cdcb6be5cd5b28&oe=557C6268&__gda__=1431126964_e2f2e78da1669e153fe8554811896ad2)
Title: Re: Yet another SR250 Tracker UK Build
Post by: cosworth on Feb 27, 2015, 16:42:53
Aquablasting looks great.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Mar 04, 2015, 06:24:26
All the aquablasting finished


Well pleased with it   :)

Wheels next

(https://scontent.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/11039299_680119325430934_5993513232133728409_n.jpg?oh=0245503135d16e2034306ee1ec9a8ba3&oe=55772626)
Title: Re: Yet another SR250 Tracker UK Build
Post by: twade76 on Mar 04, 2015, 13:22:52
Looks good, I really want to get my engine done like this but can't face the strip-down until I absolutely have to do it!
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Mar 05, 2015, 15:01:29
Just got the stuff home and took some close up photies

The finish is superb, he has even plated the bolts and honed the barrel for me   :)

(https://farm9.staticflickr.com/8589/16724979581_f92e3f0d7b.jpg) (https://flic.kr/p/rtVTJV)20150305_184443 (https://flic.kr/p/rtVTJV) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8660/16106260993_a8864aa8d1.jpg) (https://flic.kr/p/qxfNg4)20150305_184509 (https://flic.kr/p/qxfNg4) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8656/16103893584_156a6585f6.jpg) (https://flic.kr/p/qx3EvE)20150305_184502 (https://flic.kr/p/qx3EvE) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8573/16106260243_6f326a3a46.jpg) (https://flic.kr/p/qxfN38)20150305_184448 (https://flic.kr/p/qxfN38) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8629/16700310506_85cd85aef2.jpg) (https://flic.kr/p/rrKsu3)20150305_184519 (https://flic.kr/p/rrKsu3) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8572/16518922917_9ba2588fba.jpg) (https://flic.kr/p/raHNgP)20150305_184544 (https://flic.kr/p/raHNgP) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8594/16538625788_0190bc3c62.jpg) (https://flic.kr/p/rcsMfu)20150305_184638 (https://flic.kr/p/rcsMfu) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr
Title: Re: Yet another SR250 Tracker UK Build
Post by: cosworth on Mar 05, 2015, 15:55:38
Damn. I need to find someone locally that can do this or get my own setup.
Title: Re: Yet another SR250 Tracker UK Build
Post by: Spudscustoms on Mar 06, 2015, 16:54:26
Wow that all looks stunning. Very pleased to have found this thread. Fastline parts is about 15 mins from my house.

I think I'll be making some use of their services in the future.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Mar 07, 2015, 04:17:35
20 minutes from mine as well spudscustoms, I'm near Chorley, where are you?

When you go, ask to see Graham, Mr enthusiastic is the best way to describe him.    :)

They do blasting, and various plating as well as powder coating, a great Custom bike one stop shop.
Title: Re: Yet another SR250 Tracker UK Build
Post by: mannydantyla on Mar 08, 2015, 23:19:07
on the right track (no pun intended)
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Mar 12, 2015, 18:35:06
Just got some piccies from Fastline, he has finished the wheels, they look great.     :)


I'll post some close ups when I pick them up in the next few days, but before then, here are the ones he sent


Before

(https://farm8.staticflickr.com/7648/16174463164_989d641c77.jpg) (https://flic.kr/p/qDhmoy)Untitled (https://flic.kr/p/qDhmoy) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm8.staticflickr.com/7596/16796773645_253d6111ce.jpg) (https://flic.kr/p/rAgRBB)  (https://flic.kr/p/rAgRBB) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8643/16588950316_11639e5b6f.jpg) (https://flic.kr/p/rgUGYL)20150222_184232 (https://flic.kr/p/rgUGYL) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8566/16614270472_2e5e473deb.jpg) (https://flic.kr/p/rj9tMb)20150222_184208 (https://flic.kr/p/rj9tMb) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

After


(https://farm8.staticflickr.com/7616/16795685862_a9e177e8f2.jpg) (https://flic.kr/p/rAbhfJ)  (https://flic.kr/p/rAbhfJ) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm8.staticflickr.com/7638/16609207998_c8e6d6f2d5.jpg) (https://flic.kr/p/riGwT9)  (https://flic.kr/p/riGwT9) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm8.staticflickr.com/7604/16795665061_69dbedc29c.jpg) (https://flic.kr/p/rAbb56)  (https://flic.kr/p/rAbb56) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

Title: Re: Yet another SR250 Tracker UK Build
Post by: cosworth on Mar 12, 2015, 19:52:39
Ok. seriousy. I have to get this setup or find someone locally that will do it. This looks amazing.
Title: Re: Yet another SR250 Tracker UK Build
Post by: Spudscustoms on Mar 16, 2015, 18:08:47
Wow those wheels came out absolutely stunning, you mind me asking how much it cost to get them done.

Your just down the road from me, I'm in Adlington, between Chorley and Horwich.

I'm finally putting the finishing touches to my dream garage, it's been a good while coming, and I'm looking forward to no more working outside or stealing one week night a week or the occasional weekend working on my project bike at a mates unit.
Title: Re: Yet another SR250 Tracker UK Build
Post by: zap2504 on Mar 18, 2015, 12:48:45
Very nice results! Did you apply some clear spray on the wheels to preclude future rust (especially on the inner surface and spokes)? Does anyone in the USA know if this service is widely available?
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Mar 18, 2015, 17:43:34
About £100 for the wheels spudscustoms, final figure may be slightly more but only a few quid more. I'm in Coppull by the way.

Graham at fast line did apply some clear lacquer to stop future rusting. It won't last forever, but it will last until I get them stripped down over winter and get the hubs and rims painted black and rebuild the wheels with new stainless spokes.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Mar 22, 2015, 15:08:49
Well a weekend cleaning the engine and it's starting to look good, The paint on the crankcases has come off in places and I would like to get the clutch lever arm re-plated, but I'm unsure how to get it out.

I disassembled the starter motor as the alloy ends and steel body, could do with a spruce up. I'll get the ends aqua blasted and re-spray the steel part. I'll also get Graham at Fastline to re-plate the long bolts that hold the starter together.

I know it won't be immaculate but you could spend ages (and a lot of money chasing  the last bits of cleaning and trying to make it concourse), I just want it looking good and use it for every day riding.

I'm getting a bit impatient and want to start getting it built.   >:(


(https://farm9.staticflickr.com/8742/16869804046_2f27cf4aee.jpg) (https://flic.kr/p/rGJa1s)20150322_170111 (https://flic.kr/p/rGJa1s) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8691/16708280920_aba949aa52.jpg) (https://flic.kr/p/rssiNY)20150322_170123 (https://flic.kr/p/rssiNY) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8685/16894706231_a0d7920ea7.jpg) (https://flic.kr/p/rJVMyt)20150322_170129 (https://flic.kr/p/rJVMyt) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8734/16895689015_61fd76d1e5.jpg) (https://flic.kr/p/rK1PH2)20150322_170139 (https://flic.kr/p/rK1PH2) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr


You might notice the red mark on the engine number plate, that was blood after I got my little finger trapped between the starter gear and the clutch basket.   :-[  ::)  :'(

and the starter casings, plus a couple of brackets which I'll get re-plated

(https://farm9.staticflickr.com/8745/16275684923_7f75f26fb1.jpg) (https://flic.kr/p/qNe96i)20150322_170202 (https://flic.kr/p/qNe96i) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr
Title: Re: Yet another SR250 Tracker UK Build
Post by: Spudscustoms on Mar 23, 2015, 10:53:01
Looking good dude

shame about those scabby area's on the crank cases, I've got some wheel silver paint that might be a fairly close match, if you want to try it for colour match then just shout up, wouldn't of thought it would be too difficult to give the scabby area's a quick sand n skotch then a quick waft from the spray can if its a match. The area's to paint aren't really that visible so it wont matter too much if its not a direct match.

its going to look proper mint tho by the time you've had all this blasting and plating done.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Mar 23, 2015, 14:44:50
Good shout on the paint, bit, I'll have a go, if I nee some of that paint I'll be in touch, thanks for the offer.
Just picked the wheels and forks up from Graham

Quote
its going to look proper mint tho by the time you've had all this blasting and plating done


I think it will be quite away from that, maybe a bit of 'Patina' may not go a miss     8)





here are some close up's


Still a bit of residual rust, but I'll spray over these just to stop it getting worse.

(https://farm8.staticflickr.com/7285/16881840016_c0083c9131.jpg) (https://flic.kr/p/rHMQTb)20150323_172208 (https://flic.kr/p/rHMQTb) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm8.staticflickr.com/7643/16906768981_07b1eeb1f4.jpg) (https://flic.kr/p/rKZBoV)20150323_172034 (https://flic.kr/p/rKZBoV) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8727/16720316840_cb5f070b1f.jpg) (https://flic.kr/p/rtvZEQ)20150323_172202 (https://flic.kr/p/rtvZEQ) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8717/16881853666_0b7ee3b64f.jpg) (https://flic.kr/p/rHMUWw)20150323_172247 (https://flic.kr/p/rHMUWw) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8701/16720083968_d6820b39e3.jpg) (https://flic.kr/p/rtuNrN)20150323_172147 (https://flic.kr/p/rtuNrN) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm9.staticflickr.com/8710/16907759655_722308330c.jpg) (https://flic.kr/p/rL5FTv)20150323_172107 (https://flic.kr/p/rL5FTv) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

Like I said it's not perfect, but it's a lot better than it was.

I've just got to get this front brake cable outer welded and re-threaded.   :(


(https://farm8.staticflickr.com/7643/16721564409_823dacb8aa.jpg) (https://flic.kr/p/rtCowD)20150323_172233 (https://flic.kr/p/rtCowD) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr



As for the forks, I could not get the top cap's off, so I left them with Fastline, it needed heat and liquid nitrogen to get them to release!!!!!

So time to follow cosworths instructions and drop the forks internally
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Mar 24, 2015, 19:00:32
Starter ally casings, misc brackets and starter bolts all blasted and re-plated    :)

Before

(https://farm8.staticflickr.com/7605/16919554941_d838ec044d.jpg) (https://flic.kr/p/rM89dv)248361_690148807761319_2305457490335053134_n (https://flic.kr/p/rM89dv) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

After

(https://farm8.staticflickr.com/7600/16300535443_52477477ac.jpg) (https://flic.kr/p/qQqvhx)1234667_690148834427983_5767191542487670977_n (https://flic.kr/p/qQqvhx) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

Title: Re: Yet another SR250 Tracker UK Build
Post by: Spawnwheel on Mar 26, 2015, 11:19:35
Wow! It's looking great! I'm very jealous, makes me realise how much work is ahead of me on my build.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Mar 30, 2015, 13:42:57
More blasting   :D

Just need to get the 50mm spacer to drop the forks and then re-build them.

(https://farm8.staticflickr.com/7609/16792667040_cfdfc26a02.jpg) (https://flic.kr/p/rzUNS5)1610900_692925797483620_2197565221350129333_n (https://flic.kr/p/rzUNS5) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm8.staticflickr.com/7641/16980114955_1361428dc2.jpg) (https://flic.kr/p/rStwAF)11083902_692925824150284_7399299588178781543_n (https://flic.kr/p/rStwAF) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr
Title: Re: Yet another SR250 Tracker UK Build
Post by: cosworth on Mar 30, 2015, 14:40:30
Maybe try 35mm spacer and drop them a bit in the triples.

I say this to only add caution that the fender not hit the headlight under compression if you have a lowered headlight (which you should). Ditching the headlights bracket and adding some $10 fork mounts for the headlights is the way to go.

So by going 35mm on the spacers then adjust in the triples you came get the 50mm you want but go back to 35mm without fork disassembly.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Mar 30, 2015, 18:03:48
 I'll do that cosworth. I'll get 2 x 35mm and 2 x 50mm ones done. I'll try the 35 ones first.

I may end up dropping the forks through the top tree as I may want to add some clip ins above the top tree. The only problem I can see is that I may have to remove some material from the top tree to fit the clip ins.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Apr 10, 2015, 08:56:39
Wheels all built, with all the fittings re-plated.

Tyres fitted, but I'm not sure if the back is a little too big or the front needs to be bigger, I know it I will get a better idea when the forks are built and I can assemble the frame with the wheels in place, but I wonder if I made the wrong choice size wise. :-[

130/90 x 16 rear and 100/90 x 18 front (Maxxis Hi max)



(https://farm8.staticflickr.com/7653/16890327447_71f41629b6.jpg) (https://flic.kr/p/rJxkUc)20150410_124320 (https://flic.kr/p/rJxkUc) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

(https://farm8.staticflickr.com/7684/17097042181_eb3d008148.jpg) (https://flic.kr/p/s3NNZk)20150410_124342 (https://flic.kr/p/s3NNZk) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

and I think I have found the colour it will eventually be, Tech House Grey.

It's a Fiat colour

(http://www.fiatforum.com/gallery/data/500/medium/DSC05614.JPG)

Title: Re: Yet another SR250 Tracker UK Build
Post by: cosworth on Apr 10, 2015, 14:52:34
I have that tire size. MS90 on the rear of a 250 looks like a superbike tire. I just wish there were Michelin Pilot Power race in that size lol.
Title: Re: Yet another SR250 Tracker UK Build
Post by: pigp3n on Apr 10, 2015, 19:00:59
same an old 130/90-16 just came off mine. it rode fine. I replaced with a 120/90-16 only cause the tire I wanted did not come in that size. I went with a Bridgestone trailwing.
Funny thing is the 120/90 I put on there is actually a little bigger than the 130/90. Each manufacturer can have variances in how they measure and how each tire expands.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on May 07, 2015, 17:01:51
got it rolling, well of sorts.

Forks rebuilt using 15wt oil, 2" spacers and 1" off the spring. Seem a little firm but lets see how it rides before any more fiddling.

still wondering what Bars to use  :-\

Piccie shows Renthal ultra low riders, but I have managed to get the bosses machined off another top yolk, so clip-ons may be possible, but I think it may need some rearsets to complete that look. Rear is set to 300mm E2E. The shocks that came off were 320 E2E.

Existing rear mudguard seems to fit perfectly is moved forward as well which is a bonus   :)

(https://farm9.staticflickr.com/8849/17409179525_22725c60f5_c.jpg) (https://flic.kr/p/swoAxF)Untitled (https://flic.kr/p/swoAxF) by eastham_david (https://www.flickr.com/people/17059060@N00/), on Flickr

I have asked a local engineer for costs to produce some aluminium mudguards similar to the ones on this triumph, so we will see what he comes back with. I think they are more 'scrambler/tracker' than the standard rear guard.

Oh and that Triumph colour I think looks superb


(http://cdn.hiconsumption.com/wp-content/uploads/2014/06/Triumph-Bonneville-Scrambler-900-by-Auto-Fabrica-3.jpg)
Title: Re: Yet another SR250 Tracker UK Build
Post by: Spudscustoms on May 18, 2015, 18:29:19
Have a look at these and see what you think

http://www.classicbikeshop.co.uk/frame-chassis-mudguards/mudguards.html

could they be cut to size then skotched to the dull finish your after??
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Nov 23, 2015, 16:30:04
Well summers over and building is back underway.

It's been a few months as I have been waiting for the  cylinder head to be welded (the exhaust studs had gone loose and stripped). Anyway after months of waiting it's done    :)

(https://farm6.staticflickr.com/5771/23254348835_bea2df6998_z.jpg) (https://flic.kr/p/BqUBJT)Untitled (https://flic.kr/p/BqUBJT) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr


and whilst waiting, I have been looking for some side panels, I have tried all sorts including XS650/400, even SR500 ones non fitted and I thought I was going to have to have some made, until I came across these at a local breakers. Suzuki GN125 panels. They fit perfectly.    8)

 They need some attachments fabricating and then we are in business.

I priced up a lightweight, dry battery and they are £100 ($165 !!) so I opted for these panels so I could use the standard lead acid batteries that are considerably cheaper (£25)


(https://farm1.staticflickr.com/753/22627248773_d927ab13a6_b.jpg) (https://flic.kr/p/AtuyJR)Untitled (https://flic.kr/p/AtuyJR) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr


Only other awkward thing is trying to get the camshaft bearing out. It's full of media from the aquablasting and it needs replacing. Being a blind bearing (only accessible form 1 side)  it's proving very stubborn, even with heat applied to the outside of the head.

any suggestions?
Title: Re: Yet another SR250 Tracker UK Build
Post by: dualero on Nov 25, 2015, 10:49:18



Only other awkward thing is trying to get the camshaft bearing out. It's full of media from the aquablasting and it needs replacing. Being a blind bearing (only accessible form 1 side)  it's proving very stubborn, even with heat applied to the outside of the head.

any suggestions?

Maybe try the kitchen oven to try to expand the head completely. I've seen cylinders and bearing drop from Paris only putting them in the oven. I'd suggest 300F for about 30min at least
Title: Re: Yet another SR250 Tracker UK Build
Post by: zap2504 on Nov 25, 2015, 13:39:53
Not done it myself but I have read where you can fill the space between the bearing and cover with grease, then use a drift the same size as the center bore to create hydraulic pressure to pop blind bearings out.
Title: Re: Yet another SR250 Tracker UK Build
Post by: cosworth on Nov 25, 2015, 15:02:05
Not done it myself but I have read where you can fill the space between the bearing and cover with grease, then use a drift the same size as the center bore to create hydraulic pressure to pop blind bearings out.

This is how I did it. I had a chunk of round stock brass the exact size for it. Messy, but it worked.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Nov 26, 2015, 18:21:26
Cheers guys I'll have a go, the only problem I see with using the oven is I don't want the valve guides coming out as well   ::)
Title: Re: Yet another SR250 Tracker UK Build
Post by: cosworth on Nov 26, 2015, 19:39:29
That was my thinking. As much as they are pressed in...
Title: Re: Yet another SR250 Tracker UK Build
Post by: dualero on Nov 27, 2015, 06:31:51
This is how I did it. I had a chunk of round stock brass the exact size for it. Messy, but it worked.
I've heard of this technique for removing stubborn pilot bearings from car/truck flywheels, another tip I can add is that if the rod you have is not that tight on the center bore, instead of using only grease, use small strips of old rag covered in grease through the center bore, with the rod and a hammer. If it fills up, get another piece of rag and stuff it in there till the bearing is out
Title: Re: Yet another SR250 Tracker UK Build
Post by: JadusMotorcycleParts on Apr 01, 2016, 07:45:51
Bike is looking good man!  Any progress?
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Apr 06, 2016, 18:21:59
Yip, a bit slow though, Bearing out and new one in  :)

GN250 side panels, and tabs for the panels, fitted over Easter. Tank Lifted, front bobbins lowered & Battery box next on the list.

Please ignore the crap welding, it's just me tacking the stuff into place, off to a mates who will be doing a much better job.

Standard rear mudguard fitted but moved forward, and this allows for the plastic liner to still fit in front of it.

(https://c1.staticflickr.com/3/2863/33235168864_6f7db0516a.jpg) (https://flic.kr/p/SCSVNQ)IMG_2567 (https://flic.kr/p/SCSVNQ) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://c1.staticflickr.com/3/2949/33920526502_3e397969ea.jpg) (https://flic.kr/p/TFryKQ)IMG_2564 (https://flic.kr/p/TFryKQ) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://c1.staticflickr.com/3/2821/33920560302_f9eb515b3e.jpg) (https://flic.kr/p/TFrJNA)IMG_0173 (https://flic.kr/p/TFrJNA) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://c1.staticflickr.com/3/2903/34037183896_1cdc40d4fa.jpg) (https://flic.kr/p/TRKsWd)IMG_7642 (https://flic.kr/p/TRKsWd) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://c1.staticflickr.com/3/2827/34037179756_457e4f9411.jpg) (https://flic.kr/p/TRKrGQ)IMG_7644 (https://flic.kr/p/TRKrGQ) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Apr 27, 2016, 16:18:57
Well carb cleaned with the aquablaster and all hardware re-plated and then rebuilt      :)


(https://farm2.staticflickr.com/1547/26407992250_91d0210129_b.jpg) (https://flic.kr/p/GezS4d)IMG_8099 (https://flic.kr/p/GezS4d) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr
Title: Re: Yet another SR250 Tracker UK Build
Post by: JadusMotorcycleParts on Apr 30, 2016, 03:56:47
Nice!
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on May 07, 2016, 16:59:46
fuel tap cleaned and blasted now     :)

(https://farm8.staticflickr.com/7372/26780130602_f055b73a4a_b.jpg) (https://flic.kr/p/GNtaPG)Untitled (https://flic.kr/p/GNtaPG) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr
Title: Re: Yet another SR250 Tracker UK Build
Post by: JadusMotorcycleParts on May 08, 2016, 05:30:30
Hey man, by aqua blaster, do you mean water blaster or soda blaster?  Or something else entirely? Cheers
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on May 14, 2016, 04:41:48
not sure, but it's a 'Vixen Aqua Blaster'


(http://www.fastlineparts.com/media/wysiwyg/aqua-blaster.jpg)
Title: Re: Yet another SR250 Tracker UK Build
Post by: JadusMotorcycleParts on Jun 25, 2016, 14:25:33
Thats bloody brilliant!
Title: Re: Yet another SR250 Tracker UK Build
Post by: Tune-A-Fish© on Jun 25, 2016, 17:23:43
I just love the vapor blast finish so clean


Sent from my iPhone using DO THE TON (https://siteowners.tapatalk.com/byo/displayAndDownloadByoApp?rid=89466)
Title: Re: Yet another SR250 Tracker UK Build
Post by: beachcomber on Jun 27, 2016, 05:34:13
I had one of these systems years ago when I was manufacturing replica Sports cars. It used glass bead mixed with water. The ued bead / water was collected into a hopper and dried off before being recycled.

You can buy soda / sand blast pots for around £150 - £200, but it's an open air total loss system ! They give the same sort of results as shown in this thread.

Excellent work so far BTW. 8)
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Nov 23, 2017, 17:10:39
Well we at off again, other things have got in the way, but the engine re-build has started.

(https://farm5.staticflickr.com/4528/38605882681_f5bb055a76_c.jpg) (https://flic.kr/p/21PteUV)Untitled (https://flic.kr/p/21PteUV) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

The bad news is it's 2 years since I stripped it and I'm struggling to remember certain bits   :(

Some help would be much appreciated gents.

Firstly, the hole in the threaded head above the crank centreline, does anything go in it?

(https://farm5.staticflickr.com/4517/37717687225_580f782e47_c.jpg) (https://flic.kr/p/ZsZ1ma)Untitled (https://flic.kr/p/ZsZ1ma) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

and 2ndly I seem to have two bolts left over. The problem is I bagged a load of them up and sent them all for blasting and plating, silly mistake.

one looks like M4 and the other is M5, can anybody shed a light on where they go?

(https://farm5.staticflickr.com/4570/38548727766_5b1341ee9f_c.jpg) (https://flic.kr/p/21JqiKm)Untitled (https://flic.kr/p/21JqiKm) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

and 3rdly

Does the top ring (I think its the top ring) sit with the larger dia on the bottom? ie as in the Photo

(https://farm5.staticflickr.com/4554/26828904789_1e5deb78df_c.jpg) (https://flic.kr/p/GSM9FX)Untitled (https://flic.kr/p/GSM9FX) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr


Thanks in advance

Dave

Title: Re: Yet another SR250 Tracker UK Build
Post by: Pete12 on Nov 23, 2017, 23:19:07
Not sure about your bolts and hole but the manufacturer's stamp on the piston rings (adjacent to the gap or end) always goes up.
Title: Re: Yet another SR250 Tracker UK Build
Post by: JadusMotorcycleParts on Nov 26, 2017, 16:04:46
Great this project is on again!

The small bolt is your oil check bolt - that's why it's got the copper sealing washer.  It goes in the head on the spark plug side.

The larger bolt is the oil filter cover drain bolt - the lower of the three bolts that hold that cover in place.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Nov 26, 2017, 17:11:16
Cheers Jadus :)



I think I have already installed the oil check bolt, is it the one that sits right next to a cylinder head bolt? its an M5 where as the small one in the photo looks like M4

It serves me right for not doing the bolt plating in bits. I dropped them all off with the platers and they all got mixed up.

Is the threaded hole in the head in the photo for some bikes that have a tacho fitted do you know? and as such nothing goes in there for my bike?


Hopefully engine will be fully built in a couple of weeks. Might try and source a new carb mounting rubber as the old one looks a bit rough.

Then its battery tray and seat next.
Title: Re: Yet another SR250 Tracker UK Build
Post by: JadusMotorcycleParts on Nov 27, 2017, 19:31:12
Correct with the oil check bolt in the head.  The only remaining one with a copper washer like that is the one on top of the oil filter cover - used to drain the oil from that cavity when changing oil filter.  This would make sense becuase your other mystery bolt was from the same part/location.

Yes, some of the later model SR's (even most from the Spanish factory) had a tacho drive off the cam shaft - meaning a hole in the head for that.  But it is not threaded, it just had a pressed in bearing then the cable has an oring on a plug with the wire running through it.

Yeah, double check the carb boot rubber - sucks to get an air leak there that only shows itself when the engine is warm - messing up all you carb setting work.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Nov 28, 2017, 12:28:19
Cheers, after much Googling last night (and before you replied) I noticed the bolt in the oil filter cover   :)

So that's that mystery sorted, thanks for the help.

The hole in my head is threaded, its the one in the picture, just above the centreline of the cam. It is behind the top cam pulley, it looks like about an M5 thread.


My casting has the tacho take-off blanked off, ie not machined.

cheers

Dave
Title: Re: Yet another SR250 Tracker UK Build
Post by: C717 on Dec 08, 2017, 20:42:34
Great thread to read, any update?

I've just signed up looking for advice and inspiration on an SR tracker I'm just planning. Do you have a list of part suppliers you've used so far? Quite hard to come by in the UK.

Currently toying with longer rear shocks and whether the mikuno vm32 carb is worth the swap!

Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Dec 13, 2017, 17:29:49
not yet, just struggling with work and Christmas prep etc. Hopefully engine will be back together over Christmas
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Jan 07, 2018, 12:56:18
Right gents I need some help please??

Head is now assembled and finished

(https://farm5.staticflickr.com/4728/38663216475_404c034bc1_c.jpg) (https://flic.kr/p/21Ux6fB)Untitled (https://flic.kr/p/21Ux6fB) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm5.staticflickr.com/4734/39529706702_910612f1ab_c.jpg) (https://flic.kr/p/23e75Bh)Untitled (https://flic.kr/p/23e75Bh) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm5.staticflickr.com/4734/39529706702_910612f1ab_c.jpg) (https://flic.kr/p/23e75Bh)Untitled (https://flic.kr/p/23e75Bh) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm5.staticflickr.com/4683/38850387424_ff7a78b251_c.jpg) (https://flic.kr/p/22c5oDW)Untitled (https://flic.kr/p/22c5oDW) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

but embarrassingly I'm having trouble sorting the gasket/seal/spacer set-up for the head to cylinder and cylinder to crankcase.

I seem to have a plastic spacer too many in the gasket kit I bought (it's a full engine kit)

Does this cylinder to head seal/plastic spacer/metal spacer look right?

(https://farm5.staticflickr.com/4644/25689171888_bdb81fafbf_c.jpg) (https://flic.kr/p/F94HNG)Untitled (https://flic.kr/p/F94HNG) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr


and is the lower face of the cylinder to crankcase set-up right in this picture?

(https://farm5.staticflickr.com/4646/38663209605_1c2464338e_c.jpg) (https://flic.kr/p/21Ux4da)Untitled (https://flic.kr/p/21Ux4da) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr



and too finish, I'm still unaware of anything that fits into this threaded M5 or M6 hole in the head, is it surplus and only used for tacho off-take on some models?


(https://farm5.staticflickr.com/4730/25689362238_6b44568bd4_z.jpg) (https://flic.kr/p/F95GoA)Picture1 (https://flic.kr/p/F95GoA) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr


Thanks in advance
Title: Re: Yet another SR250 Tracker UK Build
Post by: JadusMotorcycleParts on Jan 09, 2018, 16:29:35
You are correct on the tapped hole in the head.  It is only used on the models with a tach drive there.

I am 90% sure you have the orings/gaskets/dowels wrong on the head and the barrel.  I couldn't find my reference photos right this minute but check these exploded diagrams to be sure:  https://www.cmsnl.com/yamaha-sr250t-1981-exciter1-usa_model8812/partslist/A-06.html#results
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Jan 09, 2018, 17:32:57
Cheers,

I'm sure the red O ring and thin metal sleeve sits in the oil way on the crankcase

i.e. the top right position here

(https://farm5.staticflickr.com/4764/25712105468_c8d1153448_c.jpg) (https://flic.kr/p/Fb6gaf)Untitled (https://flic.kr/p/Fb6gaf) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

This coincides with the same position on the lower cylinder in this picture

(https://farm5.staticflickr.com/4603/27805632639_fa0e64254c_c.jpg) (https://flic.kr/p/Jn68Ri)Untitled (https://flic.kr/p/Jn68Ri) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

The other plastic sleeve and metal sleeves in the upper face of the cylinder/lower face of the head look like this with he gasket in place

(https://farm5.staticflickr.com/4701/27805636979_0d6a869bab_c.jpg) (https://flic.kr/p/Jn6a98)Untitled (https://flic.kr/p/Jn6a98) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

The rebate/counter bore in the right hand upper corner of the above picture is quite deep and I'm sure that's where the plastic spacer sits. The picture below shows how deep that counter bore is, this is also the oil way so that's why I thought these had spate seal to the other 3 x head/cylinder bolt holes. 

(https://farm5.staticflickr.com/4761/38686323055_ab946e2919_c.jpg) (https://flic.kr/p/21Wzw2V)Untitled (https://flic.kr/p/21Wzw2V) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr


cheers for the advice and help, heaven knows I need it.   :(

(two strokes are so much easier)

I have had a look at the cylinder diagram (thanks for the link that helps a lot) and the equivalent head diagram and the seals/gaskets appear right, but I could be wrong.

Dave
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Jan 15, 2018, 16:45:22
Just about to pop new rings in and checked the sizes of the old rings, they are mainly gapped at 0.65mm ish. Took the new rings out of the packet and placed them in the bore only to find they overlap 5mm, is this correct. In my old karting/2 stroke days they rings only needed a small fettle if anything, these appear massive.

I have checked the part number and the bore size (73.5mm) and they match. Surely you shouldn't have to try and trim 5mm off them ???

if that is the case, how the hell do I do the oil control ring. I'm hoping they are just the wrong rings.

any help would be much appreciated

Ta
Dave

(https://farm5.staticflickr.com/4724/24841714327_e68457a359_z.jpg) (https://flic.kr/p/DRbhcr)Untitled (https://flic.kr/p/DRbhcr) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr
Title: Re: Yet another SR250 Tracker UK Build
Post by: JadusMotorcycleParts on Jan 22, 2018, 01:21:11
Did you figure the ring issue out?  Could it be that you have received a ring set for the US version SR250?  That was a true 249cc engine - with a 75mm bore rather than the 73.5mm bore that gives 239cc.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Jan 22, 2018, 15:23:17
That could be the case, I was going to rebuild it with the old rings, but the top ring has lost its marking so I don’t know which way round it goes. 🙄

Having had a close look at it it seems to have the same tiny chamfer on the lower and upper surfaces.

Do you think it will go in either way?

The other option is to just buy a new set and fit them, and this time hope they are the right ones. 🙄.

I may be in touch for a header and front mudguard soon. Just one question, can you have the headers made to a different pattern ie for a high mounted exhaust or do you only do them as pictured on your site?

Cheers

Dave
Title: Re: Yet another SR250 Tracker UK Build
Post by: der_nanno on Jan 23, 2018, 04:16:14
Hi Dave,

with regards to the ring: Yes one can regap them to size, but only if it's out by let's say 0.25mm or so and even that's a I am in the middle of the Sahara and need to get home to work on Monday sort of fix/bodge. The reason for that is, otherwise they will only touch the cylinder wall in two or three points and not seal properly as they are no longer round. (For those in the know: Yes, this is an oversimplification, but it helps understanding - strictly speaking neither the piston nor the rings are round, only the bore is...) So unfortunately you'll have to get the right rings for your cylinder-diameter.

The second thing: Please grease (any old grease will do, I use normal bearing grease as I have that standing around in big 1kg-jugs) up your cylinder base gasket (and all other paper gaskets on sidecovers etc., but not the headgasket), as that will make removal a lot easier and in terms of the sidecover gaskets, i.e. gaskets that won't get as hot, you stand a very nice chance of the covers being removable without destroying the gasket in the process AND sealing nicely.

Oh and aside from my other comments: Nice build, I am more and more inclined to really build a SR250 myself sooner or later. Lots of tuning potential in that engine.

Cheers,
Greg
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Jan 24, 2018, 17:40:59
I think it's easier to order some new rings so that's what I'll do, at least when I button it all up it should be sorted.

The good news is I got the top yolk assembly back from aqua blasting, all bolts , nuts etc re-plated. Graham is just going to do the controls as I am having them raw alloy as well, I'll post some piccies up when I get them back.


(https://farm5.staticflickr.com/4714/38974482875_1a079ccb6a_z.jpg) (https://flic.kr/p/22o3pUF)Untitled (https://flic.kr/p/22o3pUF) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr
Title: Re: Yet another SR250 Tracker UK Build
Post by: JadusMotorcycleParts on Jan 24, 2018, 22:15:54
Damn, that looks great man.  Nice to go all in with replating the fastenings as well.

I agree with Greg, if you trim and force those rings, they will essentially be out of round.  Best try with a new set.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Jan 28, 2018, 17:02:09
New Yamaha piston rings on their way from Bulgaria   ::)

Not a great deal done this weekend, the loom has been cleaned with IPA and a lot of elbow grease (plus the aid of a toothbrush).

Change of heart on the build this morning though, I'm removing the side panels and going for an open triangle with a 4 cell anti gravity battery under the seat.

I am looking to remove around 10kg from the bike. I spent 1/2 hour weighing stuff from the original build and it's amazing the weight that can be lost. A 4 cell Li-on battery,  plus aluminium fenders and other stuff removed or replaced, i.e. indicators, headlamp and centre stand, I will easily remove 10kg and that's before considering aluminium rims for the wheels. So target is around 110kg and 24BHP. All that should make it quite sprightly I think.   :)

Here is how the loom looked before

(https://farm4.staticflickr.com/3919/14446513753_06e04d57fd_z.jpg) (https://flic.kr/p/o1Aaek)P1050479 (https://flic.kr/p/o1Aaek) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm4.staticflickr.com/3912/14239721620_6e2e50c2a7_z.jpg) (https://flic.kr/p/nGji8J)P1050485 (https://flic.kr/p/nGji8J) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

but it now looks like this


(https://farm5.staticflickr.com/4757/39920748242_8642fc0cb8_z.jpg) (https://flic.kr/p/23PEgCN)Untitled (https://flic.kr/p/23PEgCN) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm5.staticflickr.com/4678/39242585324_1c1986b5e7_z.jpg) (https://flic.kr/p/22MJvqG)  (https://flic.kr/p/22MJvqG) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm5.staticflickr.com/4657/39920747962_64d5e55d84_z.jpg) (https://flic.kr/p/23PEgxY)  (https://flic.kr/p/23PEgxY) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Feb 18, 2018, 16:46:16
Not as much done as I thought I would get done with a few days off work, mainly due the Mrs Having decorating plans for me ::)

However I managed to source some hand rolled mudguards made to my dimensions for a bargain of £50 plus postage for both front and rear !!!!

Also sourced some tabs from eBay for attaching the battery tray and mudguard, they are the ones used to fasten Kart floor trays to the chassis rails, all for the princely sum of £5

New Hagons shock at +20mm e2e length also arrived, and a 4 cell Anti-gravity battery.


So it was fitting the rear of these and working out how to fit the 4 cell anti gravity battery to keep a clean open frame triangle.


so here are some photos

Don't take notice of the black and bare guards, I am still debating about having them black or leaving them a polished alloy.

(https://farm5.staticflickr.com/4740/38534972170_4a2171ce82_z.jpg) (https://flic.kr/p/21HcNFU)Untitled (https://flic.kr/p/21HcNFU) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

Aqua blasted top yolk and the bars fitted.

(https://farm5.staticflickr.com/4663/38534964360_194f76aa3f_z.jpg) (https://flic.kr/p/21HcLnf)Untitled (https://flic.kr/p/21HcLnf) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm5.staticflickr.com/4697/39447391045_3cf146fb40_z.jpg) (https://flic.kr/p/236Qc2P)Untitled (https://flic.kr/p/236Qc2P) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

The good thing about lifting the rear of the tank by adding extenders to the standard tank mount was that it now leaves room for the Starter solenoid, which was deeper than the battery!!!  :-)


(https://farm5.staticflickr.com/4624/40344538731_5ed79a8a14_z.jpg) (https://flic.kr/p/24t7iMn)Untitled (https://flic.kr/p/24t7iMn) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm5.staticflickr.com/4652/39447626485_afcbbe1c8d_z.jpg) (https://flic.kr/p/236Rp28)Untitled (https://flic.kr/p/236Rp28) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

The battery is tiny  !!!!!

Next job is the get the battery tray cut out of alluminium and some tags welded on the locate the battery and sit the starter solenoid holder onto.

Oh and when the voltage regulater is back from the aqua blasters, I need to fit that, I think thats going to have to go under the battery tray, which is shame as it will be seen through the open triangle, but it needs to be in the airflow.


(https://farm5.staticflickr.com/4673/39633304444_6a95c7094e_z.jpg) (https://flic.kr/p/23og3Bf)Untitled (https://flic.kr/p/23og3Bf) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm5.staticflickr.com/4602/40344807161_04c47d3404_z.jpg) (https://flic.kr/p/24t8Fzt)Untitled (https://flic.kr/p/24t8Fzt) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr
Title: Re: Yet another SR250 Tracker UK Build
Post by: JadusMotorcycleParts on Feb 24, 2018, 11:39:25
Nice solution for the tank!

I notice you have some different fork caps in?  Did you have them made or did you source them from another bike?
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Feb 24, 2018, 12:42:50
They are what came with the bike, how are they different to yours?
Title: Re: Yet another SR250 Tracker UK Build
Post by: zap2504 on Feb 24, 2018, 13:24:06
They are what came with the bike, how are they different to yours?
The ones in the USA came with press-in, held by a circlip units. Not screw-in types.
Title: Re: Yet another SR250 Tracker UK Build
Post by: JadusMotorcycleParts on Feb 27, 2018, 18:32:21
^^^^^ Exactly  ;)
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Feb 28, 2018, 05:53:39
That solution would have been easier, as we had to use liquid Nitrogen to get those threaded ones out of the forks, they had well and truly stuck/corroded   :-\

What views do you guys have on the placement of the voltage regulator? I would like to hide it out of the way to keep the triangle nice and clean, ie not mount it flat on the underside of the battery tray, but it needs to be in clean air to allow it to cool, this is especially important with the anti-gravity battery I'm fitting.

I was thinking of mounting it facing forward just below the rear tank mount, i.e. just above the air filter/carb. Any other areas you would recommend that are unobtrusive but will not affect its performance?

Ta

Dave
Title: Re: Yet another SR250 Tracker UK Build
Post by: beachcomber on Feb 28, 2018, 07:43:23
That solution would have been easier, as we had to use liquid Nitrogen to get those threaded ones out of the forks, they had well and truly stuck/corroded   :-\

What views do you guys have on the placement of the voltage regulator? I would like to hide it out of the way to keep the triangle nice and clean, ie not mount it flat on the underside of the battery tray, but it needs to be in clean air to allow it to cool, this is especially important with the anti-gravity battery I'm fitting.

I was thinking of mounting it facing forward just below the rear tank mount, i.e. just above the air filter/carb. Any other areas you would recommend that are unobtrusive but will not affect its performance?

Ta

Dave

Don't forget to take into account "heat sink" if mounted above the engine. Hardly an issue today with -3 degrees outside !
Title: Re: Yet another SR250 Tracker UK Build
Post by: zap2504 on Feb 28, 2018, 19:18:54
What views do you guys have on the placement of the voltage regulator? I would like to hide it out of the way to keep the triangle nice and clean, ie not mount it flat on the underside of the battery tray, but it needs to be in clean air to allow it to cool, this is especially important with the anti-gravity battery I'm fitting.

I was thinking of mounting it facing forward just below the rear tank mount, i.e. just above the air filter/carb. Any other areas you would recommend that are unobtrusive but will not affect its performance?
Triumph puts theirs just below the headlight on the forks. Painted flat black.
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Mar 11, 2018, 17:21:12
Its been a slow 3 weekends on the bike, the de-tabbing and blending out of the shock mount area took ages. Hopefully it will be OK when it's painted. Manicuring with a 4.5" angle grinder would be the best way to describe it, thank goodness for the Dremmel to finish off all 'the hard to get to' places.   :(
Battery tray was folded and fitted. Will be locating and finalising all the electrics in the next couple of weeks so any last minute tabs for cable ties etc can be welded into position. I am aiming to have no cable ties wrapped around the frame tubes.

(https://farm5.staticflickr.com/4774/26881923998_f5059161b5_z.jpg) (https://flic.kr/p/GXsTsf)Untitled (https://flic.kr/p/GXsTsf) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm5.staticflickr.com/4801/25881817387_ff83a0f510_z.jpg) (https://flic.kr/p/Fr65AP)Untitled (https://flic.kr/p/Fr65AP) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm5.staticflickr.com/4771/25881813167_ff3257ce24_z.jpg) (https://flic.kr/p/Fr64m4)Untitled (https://flic.kr/p/Fr64m4) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr


Please don't judge the welding, It's my first attempt   :-[ :-[ :-[ :-[    ::) ::) ::)
Title: Re: Yet another SR250 Tracker UK Build
Post by: vortexracing on Mar 31, 2018, 11:49:03
Just got back for Fastline Parts, Graham has just finished my levers and controls.

Complete strip down, aquablast, re-plate all fittings, including the electrical connectors etc.

They look superb

(https://farm1.staticflickr.com/817/40424581444_c54ca1608f_z.jpg) (https://flic.kr/p/24AbxG9)Untitled (https://flic.kr/p/24AbxG9) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm1.staticflickr.com/788/26264400307_69ac71f4b3_z.jpg) (https://flic.kr/p/G1TVb4)Untitled (https://flic.kr/p/G1TVb4) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm1.staticflickr.com/810/40240831035_e61dea5620_z.jpg) (https://flic.kr/p/24iWM6D)Untitled (https://flic.kr/p/24iWM6D) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm1.staticflickr.com/870/41092648952_3732a8a8a4_z.jpg) (https://flic.kr/p/25BdyTs)Untitled (https://flic.kr/p/25BdyTs) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm1.staticflickr.com/886/41092652682_9fb8716726_z.jpg) (https://flic.kr/p/25BdzZL)Untitled (https://flic.kr/p/25BdzZL) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm1.staticflickr.com/809/40424575584_2fda55963a_z.jpg) (https://flic.kr/p/24AbvX7)Untitled (https://flic.kr/p/24AbvX7) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm1.staticflickr.com/880/40424574844_38f77a1505_z.jpg) (https://flic.kr/p/24AbvJm)Untitled (https://flic.kr/p/24AbvJm) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm1.staticflickr.com/810/27262896558_19d1e3d45f_z.jpg) (https://flic.kr/p/Hx8tjE)Untitled (https://flic.kr/p/Hx8tjE) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm1.staticflickr.com/864/27262883938_be58dd3950_z.jpg) (https://flic.kr/p/Hx8pz5)Untitled (https://flic.kr/p/Hx8pz5) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm1.staticflickr.com/887/40424579504_0a9c950098_z.jpg) (https://flic.kr/p/24Abx7G)Untitled (https://flic.kr/p/24Abx7G) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm1.staticflickr.com/888/40424582744_c17d08f239_z.jpg) (https://flic.kr/p/24Aby5y)Untitled (https://flic.kr/p/24Aby5y) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm1.staticflickr.com/808/41135965791_1bb15afee7_z.jpg) (https://flic.kr/p/25F3ztv)Untitled (https://flic.kr/p/25F3ztv) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

(https://farm1.staticflickr.com/878/41135965121_105d696ea3_z.jpg) (https://flic.kr/p/25F3zgX)Untitled (https://flic.kr/p/25F3zgX) by eastham_david (https://www.flickr.com/photos/17059060@N00/), on Flickr

He has even blasted plated the inner connectors and switching units   :) :) :) :) :) :)

They are like new, not bad for something that was 22 years old and tatty.