Brodie's '72 Honda XL250 Motosport!

Brodie

Gold Coast, Queensland
DTT SUPPORTER
New carb arrived yesterday from Pete. Thank you very much mate.

Here is a comparison between the carb I had and the one Pete sent. World of difference. I am not sure what the carbs are made from but the original had corrosion from what I could only assume was water sitting in the bowl.

All of the external hardware on the new carb was in better condition as well so I will be using that. Just need to do a clean up of the outside and stick her on the bike!
 

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Brodie

Gold Coast, Queensland
DTT SUPPORTER
Yep. I can only imagine how bad the small passages must be on the original. That photo is even after I gave it an ultrasonic bath. Have not started on the one Pete sent yet and it is already so much better.
 

Brodie

Gold Coast, Queensland
DTT SUPPORTER
Had a chance today to give the new carb a good once over. I took it apart and took photos before giving it a wash down in turps. After that I rinsed it off and stuck in in my tiny ultrasonic cleaner with a bit of warm water and dishwashing liquid.
Another rinse after both sides were done with warm water and a blow through all passages with compressed air. Came up clean for an old carb. Photos of the process below.
After that I stuck all the bits back on and mounted it. Bike starts and idles well. Yet to give it a ride.
 

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Brodie

Gold Coast, Queensland
DTT SUPPORTER
Gave all the hardware a clean up as well. Thanks Pete for the choke mounting bracket. Looks much nicer than the one I had!
 

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adventurco

Nick Ol' Eye
DTT BOTM WINNER
Brodie on that carb there is a TINY passageway that goes through the airbox side into the side of the emulsion tube. Make sure its clear I think that's what caused mine to idle really rich and foul plugs.
 

Brodie

Gold Coast, Queensland
DTT SUPPORTER
Would that be #2 in this diagram?
 

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teazer

Over 1,000 Posts
DTT BOTM WINNER
Not exactly, but close.

#1 is the bypass that allows fuel to flow even when the throttle is closed. #2 is the actual pilot mixture outlet (discharge) and #3 is the pilot air jet.
#1,2 &3 must all be open to get the thing to idle.

On that carb, what we think of as an air screw appears to be a fuel screw, so OUT = richer. Similar to a CV carb.
 

Brodie

Gold Coast, Queensland
DTT SUPPORTER
Ok. Well I poked one of my mandolin strings through all the holes I could see to try and clear them out before I put it on for the ultrasonic bath. Seems to idle well enough.
 

Pete12

Been Around the Block
Brodie said:
Gave all the hardware a clean up as well. Thanks Pete for the choke mounting bracket. Looks much nicer than the one I had!
No problem Brodie, glad it was of some use to you. The rest of the bike is still sitting there, let me know if you need anything else.
 

adventurco

Nick Ol' Eye
DTT BOTM WINNER
#3 is what I was talking about, where it bottle necks is super tight. If you can get a string through there you'll be good
 

Brodie

Gold Coast, Queensland
DTT SUPPORTER
Starting to get the shed cleared out some so I have some room to work again. I will turn my focus back onto the XL.

No problem Brodie, glad it was of some use to you. The rest of the bike is still sitting there, let me know if you need anything else.

Thanks for the offer Pete. I may need to take you up on a few parts once I dig deeper.
 

Pete12

Been Around the Block
Starting to get the shed cleared out some so I have some room to work again. I will turn my focus back onto the XL.



Thanks for the offer Pete. I may need to take you up on a few parts once I dig deeper.
No problem at all, it's still just sitting there.
 

Brodie

Gold Coast, Queensland
DTT SUPPORTER
Back on the stand with room each side to work on.
Next job will be the rear sprocket and wheel bearings.
I also need to order a gasket kit to replace what was too far gone when I pulled some of the engine parts off.
 

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Brodie

Gold Coast, Queensland
DTT SUPPORTER
Gasket kit has been ordered. Coming from Canada so should be here in 4 weeks.
I decided to do a full strip of the bike. Never know what you will find. In saying that here is a list of dodgy stuff I never noticed before.
A nail instead of a split pin to hold the rear brake stay on.
Wrong bolts to hold the shocks on.
A missing bush in the right hand shock.
A M10 spring washer on a M8 bolt.
A captive nut that was spinning free.
Squashed shock mounts.
A missing bolt for the rear fender.
The chain guard is from who knows what model.
A small galv adaptor plate to hold the chain guard on.
The battery holder has broken due to vibrations.
The current rear sprocket is so worn the teeth are like waves.

So that's the rear end stripped.
IMG20201128194653.jpg

Tomorrow I will have a crack at the front and then see if I can take the motor out.
 

ridesolo

Who, me?
DTT SUPPORTER
DTT BOTM WINNER
Gasket kit has been ordered. Coming from Canada so should be here in 4 weeks.
I decided to do a full strip of the bike. Never know what you will find. In saying that here is a list of dodgy stuff I never noticed before.
A nail instead of a split pin to hold the rear brake stay on.
Wrong bolts to hold the shocks on.
A missing bush in the right hand shock.
A M10 spring washer on a M8 bolt.
A captive nut that was spinning free.
Squashed shock mounts.
A missing bolt for the rear fender.
The chain guard is from who knows what model.
A small galv adaptor plate to hold the chain guard on.
The battery holder has broken due to vibrations.
The current rear sprocket is so worn the teeth are like waves.

So what you are saying is that it's in typical DTT project bike condition? :D :cool:

Good luck, you'll do a great job!
 

Brodie

Gold Coast, Queensland
DTT SUPPORTER
Ha! Not wrong there. I think I might have gotten away lucky compared to some of the bikes I've seen.
Looks like someone did care about her before the bloke we bought it off.
Rear wheel bearings look new. Feel pretty good.
I can't recall ever replacing them but they are the brand I use.
As for the sprocket. That's another story.

The old one was a well and truly worn 44t.
IMG20201129105316.jpg

The new is a stock 48t
IMG20201129105330.jpg

Bit of a difference. Should have more pep with the new sprocket.
IMG20201129105418.jpg
 

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