xl250s brat tracker mashup

[nixon]

Well I do love projects.

Wanted something dual shock, and although I love cafes - i kinda need a bike more upright as I ride with one arm. cable clutch also easier to modify for dual levers maybe? I now know of a cool gadget - dual brake/clutch in one! http://www.clake.com.au - hindsight I would have got hydraulic clutch bike..next one will be.. Would have preferred 400cc + but its kinda more for the shed time than the lap time. was going to use it for the forest / trails only..but I live miles away from any and figure can still trail ride on dual tyres.. ANYWAY Havent ridden this bike..after I bought it It fired up after 2-3 kicks and gears feel tight so thats a start..

 

[nixon]

first thing to rebuild both wheels ..and drop mammoth 23" front to 19" 2.15 Excel taken off a YZF450.

 

[nixon]

the rear rim was salvageable..just. the worst corrision was under rim lock ..the rest was just surface which ground off with 3m wheel.. etched primed and rattle enamel black

 

[nixon]

while waiting for buchanan spokes polished some pieces..

 

[nixon]

dropped 2" thru triple clamps.. may raise with the 19 rim? have to see

 

[BoJordan]

YES FINALLY, someone else with the same bike as me! I purchased my xl250s about a month ago and I am stuck midway thru stripping the engine, bloody stubborn cylinder head bolts!!! Need to wait for money for a impact wrench or something. Looking good so far mate! I've subscribed and keen to track your progress. What are you going to do in regards to exhaust? Stock or custom?

 

[nixon]

hey, def custom.. still deciding one black or chrome shorty where the existing old supertrap is, or keep the 2 pipes split - underneath or lower each side.

Got deliveries, highly recommend quality and help from buchanan re custom length spokes! dropped the 53 t rear for a 44t..hope she can pull it!


The removable plate on the front hub, juggling 18 spokes one handed.. sheesh its really a patient builder. It aligns 4 different ways to the rim- i know that now!!

The rear is pretty true but front dropped off to get trued - ive spent enough time on it

 

[nixon]

cut & fitted 45° silicon intake and ramair filter.. rear back on..semi polished front forks

cant wait to alter subframe..raise and flatten, contemplating getting a MIG..or leave it to the experts. im leaning towards latter for a quicker, better finish!

 

[nixon]

YES FINALLY, someone else with the same bike as me! I purchased my xl250s about a month ago and I am stuck midway thru stripping the engine, bloody stubborn cylinder head bolts!!! Need to wait for money for a impact wrench or something. Looking good so far mate! I've subscribed and keen to track your progress. What are you going to do in regards to exhaust? Stock or custom?

So you have a socket that fits the bolts tight? Have you tried extending your leverage with a 24mm spanner..or a piece of steel pipe that fits over your rachet..2 or 3 feet long will bust those bad boys off. best few dollars u will ever spend at a steel merchant.

 

[BoJordan]

So you have a socket that fits the bolts tight? Have you tried extending your leverage with a 24mm spanner..or a piece of steel pipe that fits over your rachet..2 or 3 feet long will bust those bad boys off. best few dollars u will ever spend at a steel merchant.

Yeah mate, the 14mm is snug and it got the others off, it's just this one particular one that is struggling to move, I have cracked it, but it only rotates maybe 2-3 rotations before it creaks and stops. I might look into some steel tubing for that extra length for more torque because impact wrenches are going to bust my wallet I think. Cheers for the suggestion. Those wheels are looking shmick by the way!

 

[nixon]

have u tried penetrating fluid? or even wd40 etc?
before you attempt to remove again, try acetone (bunnings ) and vegetable oil in a spray bottle as a penetrating oil..works better than WD-40 apparently!
I tried it on some rusted bolts and worked good.leave the stuff on overnight .
definitely add 2-3ft + of leverage and should be ok. good luck!

 

[BoJordan]

Have used bulk wd40!!! I'll give acetone and vegi oil a go, cheers for the help. I'll stop hijacking your post now haha. I look forward to see more progress, it won't be too long before I post my own thread, I just want more progress myself first.

 

[nixon]

wheels trued and back on..ordering muffler, fenders and sorting seat height and sub frame next.

Any input appreciated, im kinda tall and wanted to raise the seat frame, if I cut and re weld or expand the webbing of original shock mounts would that be ok?

 

[nixon]

got a welded section in to raise tank/seat.. stock felt way to low for my height. still need put one or 2 bars to support, and plenty of space for battery holder

still deciding plywood or fibre-glass seat base.hmmm- edit - def fibreglass to get snug fit with tank..

 

[nixon]

finaly got a day to myself.. first time welding in 16 years.. inverter arc welders are pretty cool..super smooth..you dont need to 'strike' like the old ones..

welding tank support and sleeve. First time fibreglassing and no idea how it will turn out. mildly optimistic! It seems some guys just do one layer to start..then add more..others 3 layers straight up. ended up with some areas 2 or 3..but not all over. glassed 4 1/4 bolts in .

 

[BoJordan]

Good to see this being worked on some more. What rear shocks are those by the way? There's a set just like them on eBay for super cheap and I dunno if its worth it or not

 

[nixon]

That's where I got them..decent quality if they are the ones in aust,

 

[BoJordan]

That's where I got them..decent quality if they are the ones in aust,

Yeah pretty sure I know the ones u r talking about. They look good!

 

[nixon]

Seat sorted. the checklist gradually shrinks..exhaust and electrics next..

Any ideas for tank colour? Baby blue /aqua? Metallic grey or black?

 

[nixon]

local guy bent up a middle section, packed shorty with steel wool then pink batts. not too loud..