1981 Yamaha SR250 Cafe Racer

Hey all! It's been a while between updates as I've been busy with christmas and the new year, but I have got a lot done on the new wiring. Happy new year!

I'll be doing a dedicated and more detailed post for the wiring process, so here's a brief overview of my progress.

Let's begin with .. lots of wire ..

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Having gone over the wiring loom Chris has designed, I roughly layed out the components as I will package them inside the components box on the bike .. from left to right, a Narva integrated flasher unit, a 70 amp starter relay I will be using instead of a solenoid, two mini relays for the lights and ignition, and a 50 amp automatic reset circuit breaker. A fuse box is located on the bottom.

n704951495_1630668_5497.jpg


Now .. Narva make beautiful fuse boxes, but they only come pre-wired if you buy a 12 circuit box, which is too big for my application, the rest have tabs coming out of the sides for use with spade terminals. This is a bit uncouth and takes up a lot of space.

n704951495_1630667_5154.jpg


So .. never to be discouraged, I pressed the terminals out, trimmed the tabs off, drilled a 1mm hole in the side of the part that clips in underneath, and soldered fly leads directly to them .. and hey presto! a pre-wired fuse box. Neat!

n704951495_1630669_5857.jpg


I sunk the fuse box into the lid of the components box to allow access to the fuses without removing the lid .. I then had to make some mounting tabs out of 19mm ally flat bar to widen the fuse boxes mounting legs and push it back with nuts and m6 threaded cap head bolts. Fiddly but a nice result .. it will be dust sealed around the edges.

n704951495_1630671_6518.jpg


I've also finished the battery tray and hold down .. which I'll take photo's of this afternoon!

Cheers,
Ben
 
Hey,
I finished the battery box, tie down and electronic components box and mountings.. here it is painted on the bike ..

n704951495_1640126_1734.jpg


The fuse box is integrated into the lid so you can access the fuses just by taking the seat off (which will be attached by four wing nuts) .. it is probably a little over engineered but the whole assembly including the mounting bolts and box / battery tray etc weighs maybe a kilogram so it's still a huge weight saving overall.

n704951495_1640127_2291.jpg


A view underneath .. the inner guard I fabricate will protect this from water spray and debris from the wheel.

n704951495_1640128_2865.jpg


Cheers,
Ben
 
At first I was'nt diggin your box, but man I was WRONG that is sweet. Very nice set up. Hats off man.
 
Awesome work so far. I'm dying to see what kind of seat you come up with. I've all but given up on trying to come up with a cafe style seat on my SR250 due to the angle of the frame and the fact that my stock side covers wouldn't line up at all with a flat seat but I'm still on the fence waiting to see how yours turns out.
 
noahdog said:
I'm dying to see what kind of seat you come up with. I've all but given up on trying to come up with a cafe style seat on my SR250 due to the angle of the frame and the fact that my stock side covers wouldn't line up at all with a flat seat but I'm still on the fence waiting to see how yours turns out.
Click to expand...

Well a classic SR cafe racer involves ditching the side covers. Also, its an easy job for a competent welder / metal worker to cut the sub frame, such as my mate had done recently for $200 AU http://sr500forum.proboards38.com/index.cgi?board=Suspension&action=display&thread=2609
 
I thought you might get a kick out of this. Here's a pic of the newly added kick start on my SR250. Probably about time to clean up the garage. ;)

KickStarter.jpg
 
WTF! that is awesome! i read your previous post on how you acquired it and i was thinking of adding a kick to mine aswell.. hard to fit up? any mods required on the casing etc?

I have a 2002 model i was wondering if i could do the same!

Ben if you were interested there's an xt250 kick start shaft assembly on eBay at the moment http://cgi.ebay.com/ebaymotors/1984-Yamaha-XT-XT250-Used-Kickstart-Shaft-Assembly_W0QQcmdZViewItemQQ_trksidZp3286Q2em20Q2el1116QQitemZ180302917510QQptZMotorcyclesQ5fPartsQ5fAccessories
 
That kick start looks amazing! I want one but funds are needed elsewhere to finish the bike first.. but I'm extremely thankful you went to the trouble of figuring out what parts are required so I can add it later if I choose. I wonder how it looks in the frame .. does it tuck in nice and is there plenty of clearance?

Anyways .. sorry it's been so long between updates but I've been busy fixing my other mode of transport .. the one that actually works (well, in a fashion..) at this point - my car. Fitting a new clutch, cv's and going through most of the ignition system with new parts has taken up a lot of time that should rightly be spent on the bike ;)

A big one is coming this afternoon though ..
 
It tucks in nicely next to the carb so clearance shouldn't be a problem when I put it back on the frame. I did ditch the stock kick start lever that came w/ the assembly that I bought on Ebay. It was an ugly dirt bike part so I picked up a nice used one for an XS650 on Ebay for $15 or so. I know it's just me but I swear it makes the engine look bigger. ;)
 
Looking at the pick, I just don't understand how that kicker works. It weird that its located on the top rather than a horizontal position. BUt again, even looking at the photo and with the kicker folded out, how does that work? It looks like it goes left to right rather than up and down. I guess I am just used to the Honda type of kickers. Sorry if I am a dope and just not getting it.
 
I'll try to remember to pull the cover off and get a pic of all the inner workings tonight at our weekly bike night and post them tomorrow.
 
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