Brodie's '72 Honda XL250 Motosport!

[Rider52]

Great fix!!! The footpeg mounts are known weak spots on the XLs. The local Honda dealer built an XL350 into a pretty decent unlimited MX racer. While racing he made a hard landing and both pegs broke. He landed crotch first on the tank. I immediately modified my XL250 peg mounts.

 

[killerx]

Is it the mounts or bolts?

 

[Rider52]

Is it the mounts or bolts?

Both. A poor mount design that relies on the bolt integrity. Some of the SL/XL bikes had a peg extending from the frame which fit into the peg mount and only used one bolt. Other's had two bolts and didn't use the peg mounting system. Neither of these methods were meant to hold a large person doing jumps.

 

[Brodie]

Haven't gotten too much done the past week. Night shift always puts a damper on progress.
One of the boys at work fixed up the bolt hole for me. Drilled out to 12mm and put a 10mm helicoil in it. Not the best fix but better than it was.
I also started cleaning all the bolt holes on the frame and swing arm and running a tap through them to clear out the gunk and grime that had built up.

 

[Brodie]

Also bought a new swing arm bolt and sleeves.
The owners manual shows 2 greasing points in the bolt. My current one does not have that. Had a look online and it seems some of the bolts do and some don't.
I would prefer to be able to grease the swing arm externally. The sleeves are different as well. The current ones were a straight tube. The new set have a hole and grooves to help distribute the grease.

On that note, has anyone added grease nipples to a swing arm or frame for the pivot bolt. I know it is overkill to put one in the frame as well but this is the time to do it.

 

[Rider52]

On that note, has anyone added grease nipples to a swing arm or frame for the pivot bolt. I know it is overkill to put one in the frame as well but this is the time to do it.

I've seen it done on enduro bikes.

 

[Maritime]

Yes I have seen it and have them on my GL. Also had them on my CX swinger. I think Trek added some to a couple of his builds like piglet and rhe 400f's

 

[irk miller]

They came stock on a bunch of bikes, and I don't see any reason not to add them if they didn't.

 

[idahofrank]

This thread brought back memories, I had to post a picture of my 1972 XL250. We ran it 1973/1974 Nelson Ledges 24 hour road race.

 

[Brodie]

What a great shot. Is that a different front end on there?

 

[idahofrank]

Brodie,, all stock except a CB350 wheel and fender fitted. Oh, and a CB500 fuel tank along with a 7" headlight.

 

[killerx]

This thread brought back memories, I had to post a picture of my 1972 XL250. We ran it 1973/1974 Nelson Ledges 24 hour road race.View attachment 230389

That's awesome!

 

[Brodie]

Been flat out at work the last few days. Haven't had a chance to get much done.
I am waiting for the new swing arm bolt and sleeves to arrive so I can have some brass bush spun up.
The rubber clutch adjust plug Irk sent has arrived which is one more part ticked off the order list.

 

[irk miller]

Been flat out at work the last few days. Haven't had a chance to get much done.
I am waiting for the new swing arm bolt and sleeves to arrive so I can have some brass bush spun up.
The rubber clutch adjust plug Irk sent has arrived which is one more part ticked off the order list.

That's awesome. It got there quicker than I thought it would.

 

[Brodie]

Not much progress lately. Had one of the boys spin up some brass bushes for the swing arm to replace the old worn plastic units.

 

[Brodie]

Waiting on the weather to dry out so I can paint a few things. Took some parts down to the local car wash and used the "tyre/engine cleaner" on them. Not sure what it is but it moved all the dirt and grime very easy.

 

[Brodie]

Still raining and humid.
I painted anyway, doesn't look like it will let up soon.
In other news. Brass swing arm bushings.

 

[Maritime]

Nice

 

[Brodie]

Dropped a bucket of parts off to get powder coated today.
Should be a week and I will have them back.
Just some smaller parts like engine mounts and such.

 

[Brodie]

Not much of an update but here it is.
Started trying to remember where everything went to out it back together.
Had to get the tap and die set out to sort a few of the threads on the powder coated parts.
Also started to install the All Balls taper neck bearings but decided to wait until I could use the press at work rather than beat on them with a hammer.