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Author Topic: Yamaha SR250 Restoration - Built by a schoolboy  (Read 15043 times)

Offline benarmour

  • Posts: 98
Right, so i've not been regularly updating this, but i have been working on the bike! (I'll get round to updating ya'll on where this thing is at in a day or two...)

So i'm trying to swap out the bottom forks of one set of forks with the top half of another set of forks (all 4 forks are sr250 forks), and before i've even got anywhere, i've already reached a dead end!  :-\

I can't manage to get the allen bolt removed from the bottom of the forks, have you guys got any advice as to what i could try here to loosen the bugger?



Second question is what on earth do i do to remove this? on most fork disassemblies i've seen, there's something here that you screw off, but on my forks it just looks like a chuck of rusty metal...
Wanna hear a joke about my arm? it's humerus

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

Offline jay_kent

  • Posts: 1297
  • 1979 cb650
    • Cafe build blog
Re: Yamaha SR250 Restoration - 'What does this bit do?'...
« Reply #11 on: Oct 24, 2011, 21:25:03 »
At the top of the forks there is a solid plug with an o-ring around it that is kept in place with a metal c-clip. By the looks of it, the plug is pushed in already, and is stuck there by rust. Put some penetrant in there and let is soak for a few days. Did you drain the oil out of them yet? Than after a few days, really push on them and see if the slug will budge. If it does great. Take a small pic or awl and try to work your way at that c-clip. It's that ring close to the top of the tubes.  Once that is removed push on the top tube again and try to get that slug out. Make sure your face is not over the top, cause when/if it lets go that slug will hit you in the face and soak you with oil.

As for the bottom, it's strickly going to be force. I put the long end of the Allan key down the fork, then with steel pipe or the closed end of a large wrench I used leverage to get it out.

Do the top first.
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 benarmour

  • Posts: 98
Re: SR250 Restoration - Built by a schoolboy
« Reply #12 on: Jan 03, 2012, 16:00:57 »
So i've REALLY not been frequent with these posts, but i have been getting work done on this thing!
Cheers for the help there jay, i'll update the fork situation in a little bit...

First though, i've been doing some cleaning/painting on the frame. pretty simple, wire brushed the old paint/rust off, primed, then shot a couple of layers of gloss black, followed by a clearcoat. Here we go:


Simple as that!

Then moved onto the tank, which took quite a bit more work...........
There we a couple of pretty sizeable dents in the tank, and multiple smaller dents and scratches, etc. Whacked a bit of bondo on them, followed by a bunch of sanding and tidying up, which acheived this:

Then came some more work because i wasn't quite happy with it, followed by some primer and some colour, which got me to this point:



More updates to come soon....
Cheers fellas!
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 - Built by a schoolboy
« Reply #13 on: Jan 03, 2012, 17:42:49 »
Then work got underway on the wheels...
Took them off the bike, which was simple enough seeing as how half the brake line/speedo cable/etc. weren't included when i got the thing ;)
These where how they were looking (I deduce, although i could be very wrong, that the previous owner attempted a white rattlecan job on the rims):


So i got to work getting the white paint/remaining fragments of chrome/rust off of them, and then attempted my own little paint job in gold. I tried it and just wasn't feeling it when i was done. This combined with not being sure how well it'd hold up to road chips and the like, and i decided to go to a pro and get them powdercoated:


Super happy with these!

Replaced all the bearings, which involved using a collection of 'tools' including a flathead screwdriver, a couple of random bits of metal i found lying around, a chisel, and a meaty hammer  :o i know, i need some proper tools, but being in school and having no job doesn't go hand in hand with purchasing quality goods...
Installed bearing:


Just need to get some rubber put back on these things and they'll be ready!
Wanna hear a joke about my arm? it's humerus

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

Offline jay_kent

  • Posts: 1297
  • 1979 cb650
    • Cafe build blog
Re: Yamaha SR250 Restoration - Built by a schoolboy
« Reply #14 on: Jan 03, 2012, 21:28:41 »
Great work on the tank. looks perfect Maybe a gold stripe on there to tie the tank and rims together
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 benarmour

  • Posts: 98
Re: Yamaha SR250 Restoration - Built by a schoolboy
« Reply #15 on: Jan 04, 2012, 18:01:56 »
Well, interesting you say that.........


« Last Edit: Jan 04, 2012, 18:04:52 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 jay_kent

  • Posts: 1297
  • 1979 cb650
    • Cafe build blog
Re: Yamaha SR250 Restoration - Built by a schoolboy
« Reply #16 on: Jan 04, 2012, 19:02:44 »
lol, good work. maybe a dark line around the lettering to set it off would look the shit. That tank is so clean
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 benarmour

  • Posts: 98
Re: Yamaha SR250 Restoration - Built by a schoolboy
« Reply #17 on: Apr 02, 2012, 19:05:35 »
Been atrocious at keeping this updated, but here we go:
Been doing some cosmetic work on the engine, managed to get it all cleaned up nice, painted most of it in a flat aluminium (that's 'aluminum' for all you over that side of the water), and polished up some accent pieces:



Also, done some work re-upholstering the seat. The original vinyl was horribly tattered, so i decided to rip it all off and cover it in a nice leather jacket i found:
From this

to this:
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 - Built by a schoolboy
« Reply #18 on: Apr 02, 2012, 19:15:39 »
So the swinger that was on the bike when i received it had a major problem, the bottom of it looked like this:  :o

So bought a replacement one off good old ebay, cleaned it up a bit and voilá!


Got some more polishing work done on the forks, and replaced the old oil in there while i was at it. Managed to pick up a couple of decent tyres too, so i can put the wheels back on the frame soon, exciting timessss!
Wanna hear a joke about my arm? it's humerus

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

Offline MILKY

  • Posts: 291
  • cafe con leche
    • Garage Artists MC
Re: Yamaha SR250 Restoration - Built by a schoolboy
« Reply #19 on: Apr 03, 2012, 07:40:06 »
this is agreat build..

i'm about to start my own sr250.. i'm a complete novice 8even though i'm nearly 40!)... so i'll be learning from you!