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Author Topic: Yamaha SR250 Restoration - Built by a schoolboy  (Read 13396 times)

Offline benarmour

  • Posts: 98
Yamaha SR250 Restoration - Built by a schoolboy
« on: Jul 18, 2011, 16:10:40 »
As the subject title says, i'm restoring a 1981 sr250. Rather, that's what i'm trying to do...
The subtitle for the build is "What does this bit do?" due to the frequency of this phrase popping out of my mouth throughout the length of this build. I can admit that I don't have a flippin' clue about motorcycles. As a 15 year old in the UK, i'm much too young to legally be able to ride, meaning i don't even know the little bits of info you learn about your bike through riding them. None of my family are bikers, so i don't have that experience. I literally don't have a clue what i've got myself into by starting this resto project...
We'll see how it goes.......

Onto the bike: An 81 yamaha sr250, pretty uncommon in the UK i believe. I got it as a total wreck! We'll, i'm not sure it even qualifies to be called that. Multiple parts were missing, and what was there was rusty or partially broken, a result of the bike not being ridden in 15 years, being unloved and being open to the elements for all of that time.
The shots below show the situation...









« Last Edit: Jan 03, 2012, 17:29:38 by benarmour »
Wanna hear a joke about my arm? it's humerus

My SR250 Resto - http://www.dotheton.com/forum/index.php?topic=27744.0

Offline VonYinzer

  • DTT SUPPORTER
  • *
  • Posts: 18342
Re: Yamaha SR250 Restoration - 'What does this bit do?'...
« Reply #1 on: Jul 18, 2011, 17:54:18 »
Ya man... Thats rough alright. First thing you need is a proper shop manual. Than go from front to back and start a list of whats missing.

Are you doing a factory restoration (putting it all back to showroom condition) or customizing it?

Keep at it, ask questions when you have them (lots of smart idiots here ;) ) and have a good plan from the beginning.

Good luck my man, and keep the updates coming.

Like a river that don't know where it's flowin'
I took a wrong turn and just kept goin'

Offline jay_kent

  • Posts: 1297
  • 1979 cb650
    • Cafe build blog
Re: Yamaha SR250 Restoration - 'What does this bit do?'...
« Reply #2 on: Jul 18, 2011, 21:19:30 »
as for the engine, same engine on the tt250 and xt250 for the same years.

if it needs piston rings, don't bother trying to find one for the sr250, it shares the same part number as the xs650. tends to be cheaper.
and Yea that thing is rough as hell.

+1 on the shop manual

and don't worry about questions, we've all started somewhere. There's a lot of 250's kickin' on this site now

DTT build thread - here
More pics at my Cafe build blog - Here

"And yeah David...you're pretty much bugshit nuts just like the rest of us." ~Swagger

Offline DvoSpeed

  • Posts: 37
Re: Yamaha SR250 Restoration - 'What does this bit do?'...
« Reply #3 on: Jul 18, 2011, 21:50:34 »
Wow that's definitely a project bike! As someone in a similar situation, I can honestly say that you will learn SO much with this bike. It's also important not to let it overwhelm you. Do one thing on it everyday after school/work even if you don't feel like it. If you feel like you've done well that week reward yourself with a new part or helmet or something sweet to keep you motivated.
'66 Suzuki X6 Hustler Cafe
'67 Suzuki X6 Scrambler Resto
http://www.dotheton.com/forum/index.php?topic=25808.0

Offline benarmour

  • Posts: 98
Re: Yamaha SR250 Restoration - 'What does this bit do?'...
« Reply #4 on: Jul 19, 2011, 17:58:23 »
Hey guys, thanks for the advice :) I've managed to find a shop/repair manual on the net, and i've read through that a couple of times, so i've got a bit of an idea on a couple of things like disassembly.
Thanks for the info jay. Due to the fact that i'm on the tightest budget ever (i'm in school so have literally no income), i'm not currently looking to replace the piston. I've had a look at the cylinder and the piston, and both seem in reasonable condition, though what would i know? haha I manually turned over the engine a couple of times the other day, and i could feel the air rushing out of the spark plug hole. does that indicate a good air seal?
VonYinzer, the plan's to get it back to 90% factory, the only main exception being paint. I'm going for a green-blue tank, gold wheels, black frame, white fenders, and a few gold accents here and there. Also, i might stray from the factory finish where i have difficulty finding exact replica parts, such as the mirrors and indicators....

I've had the bike for a few months now, so i'll put up some more info and pictures to show where i'm currently at in the next couple of days!
Wanna hear a joke about my arm? it's humerus

My SR250 Resto - http://www.dotheton.com/forum/index.php?topic=27744.0

Offline benarmour

  • Posts: 98
Re: Yamaha SR250 Restoration - 'What does this bit do?'...
« Reply #5 on: Jul 27, 2011, 08:43:34 »
So guys, i need to call on some help from you:
I'm trying to replace my bearings, and have struggled and managed to get all the wheel bearings out, but i'm struggling to get the sprocket carrier bearing out. I'm not sure on how to take the seal out so that i can get at the bearing...
Here are a couple of pictures, i'm hoping that from them you can deduce what i need to do...




thanks in advance!
Wanna hear a joke about my arm? it's humerus

My SR250 Resto - http://www.dotheton.com/forum/index.php?topic=27744.0

Offline sham

  • Posts: 309
Re: Yamaha SR250 Restoration - 'What does this bit do?'...
« Reply #6 on: Jul 30, 2011, 09:58:47 »
Sorry I have no clue, so this won't help a bit.
But keep at it - I saw a couple bikes similar to that when I was looking for a project - they scared me off.
Hope it goes well for you.

Offline benarmour

  • Posts: 98
Re: Yamaha SR250 Restoration - 'What does this bit do?'...
« Reply #7 on: Jul 30, 2011, 13:12:26 »
haha, cheers man!
I ended up getting the seal out; i just needed to apply a bit more force than i had previously been willing to apply (didn't want to break anything...)

The only reason i started with a bike this bad was that i was given it for free. I had asked around a bit for a project bike, and one day a family friend rolls up in a white van and throws it out the back; i was stuck with it...

Like you, i'm a complete novice, but i'm enjoying every little bit, even simple things like getting an engine bracket all nice and painted :P
Wanna hear a joke about my arm? it's humerus

My SR250 Resto - http://www.dotheton.com/forum/index.php?topic=27744.0

Offline sham

  • Posts: 309
Re: Yamaha SR250 Restoration - 'What does this bit do?'...
« Reply #8 on: Jul 31, 2011, 02:31:11 »
Haha its a good feeling aye?
I guess if you got it for free you don't have anything to lose. I have to stick at it now I've forked out cash for mine :P
But yeh, keep it up.

Offline benarmour

  • Posts: 98
Re: Yamaha SR250 Restoration - 'What does this bit do?'...
« Reply #9 on: Aug 02, 2011, 05:58:03 »
I'm off to india to do some charity work for a couple of weeks today, but just thought i'd update this thread with a little progress...

Well, it was my birthday yesterday (still not legal to ride...), and i got a bunch of much needed parts! i've struggled for the last 6 months trying to find bits and pieces for it, but over here in england parts are few and far between, and when some of them do come up, money can sometimes be a problem, as i'm sure many of you guys can relate to. But yeah, got a bunch of parts yesterday! here are the pics...

Brand new brake light switch and new bolts for the whole engine and carburettor


Levers, rectifier (i've already got one so if anyone needs one, get in touch) and a flasher relay


Speedo and cable (quick question: speedo shows 38000 miles, but the engine has run far fewer. should i just leave the odometer as it is, or is there any way that i could get into it and change it to match roughly the mileage the engine's gone?)


Handlebar controls (the only place i'd seen these online was in canada, so i'm made up with getting them!)


And my favourite of all, the headlight!

When i return from india i'll get round to posting pictures of where i'm up to with the tank and wheels and the rest of the bike....
Wanna hear a joke about my arm? it's humerus

My SR250 Resto - http://www.dotheton.com/forum/index.php?topic=27744.0