'87 XR250 + a box of parts = project time

Discussion in 'Thumpers' started by Olas, Feb 5, 2009.

  1. Olas

    Olas the darkness

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    I couldn't pass this deal up, it's titled, didn't cost much at all and it's all there (as far as I could see). Plus, I love a good project! :evil

    I was able to score some info from the previous owner (PO) and a couple of receipts that were in the box. The receipt, from Al Bakers XR's Only, says that, in May of 1994, a NIKS rod kit, 76mm piston and a gasket kit were ordered. Another receipt suggests the cylinder was "Bored 120" of an inch - Honed w/ a Rigiotner flex hone: .0015" clearance as per customer's orders, would recomend more" .

    Apparently, from what the PO told me, soon after this work was done the bike was not ridden for too long because the bike aparently started smoking soon after the work was done. They took the bike in to a dealer who quoted about $2000 worth of work and they said no. Ever since then the bike's top end and other parts have been sitting in boxes. He thinks the valves weren't adjusted right. I'm not sure what to think.

    Did the bike run low on oil? Did an oil line get clogged? After these upgrades were done, was something not done correctly? I'll have to figure these things out. I need to buy a service manual before I get started. I'll probably end up splitting the cases because who knows what's in there after all these years....It will be a little while before I can get started on this project but it will get done and it will get done right. Here are some pictures from today:

    The bike:

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    Couple of boxes:

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    Top end:

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    Pictures of the piston:


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    #1
  2. Olas

    Olas the darkness

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    So here's where the immediate trouble begins, the cam shaft and rockers don't look good at all.

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    #2
  3. Olas

    Olas the darkness

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    [​IMG]

    I'll spend the next couple of weeks reading and learning about the bike. I know i've seen a couple of threads about these bikes here. A service manual is for sure going to be needed and, of course, the advice from you folks. What do you guys think happened here?
    #3
  4. jgrady1982

    jgrady1982 Been here awhile

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    To me (complete amateur) looks like no oil. Perhaps an oil line was clogged, starving the top end of oil. Take an air hose to all the oil lines and blow the heck out of them. Also replace all the screens. That could be a good cheap start. Looks like you may be purchasing a new CAM and rockers though. Keep us posted - Jack
    #4
  5. Reposado1800

    Reposado1800 Juicy J fan!

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    Looks like fun. I was broke during the late 80's and early 90's when these bikes ruled the earth or I would have had one myself.
    Take off the right side cover and check the clutch and oil pump for wear. It could be as simple as the previous owner busted a ring trying to put it together. That cam and a couple of rockers are finished... but you knew that. 1 and 1/2 thousandths clearance in the bore is too little for an air cooled motor. IMO. It was very common for people to punch these bikes out to a 280cc
    #5
  6. Olas

    Olas the darkness

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    Both you and the machinist who did the work think this...why do you think the PO had it done this way? Was it maybe recommended by XR's only at the time?
    #6
  7. Olas

    Olas the darkness

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    So far, I'm looking at replacing all bearings, camshaft, rockers, piston and maybe the valves...Definitely new valve seals and new cam chain. Hoping I can just rehone the cylinder and use another 76mm piston instead of going up another size.

    In the end I want this bike to be reliable and bulletproof, so I would assume that it's best to stay with stock engine components. There's lots of aftermarket components for these bikes, which is awesome. Any recomendations here will be appreciated. I can clearly see after a quick search that finding the parts to make this bike run won't be a huge issue, finding some time will be, though!
    #7
  8. Jeremy1981

    Jeremy1981 shopping for a ride

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    I may not be able to contribute anything useful to the technical knowledge here, but I sure can :lurk like a pro! :D :clap
    #8
  9. Blakebird

    Blakebird Solo Backwardo

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    A complete engine gasket kit will include valve guide seals (it did w/ my XR600). I would stay with stock rockers and cam like you say - the oem rockers for my 600 were ~$41 each.
    #9
  10. Olas

    Olas the darkness

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    Thanks for the info, Blake! I've been searching for parts and pretty much everything I need I could get through Service Honda and Xr's only it seems...I also came across this ebay item:

    http://cgi.ebay.com/ebaymotors/_Motorcycle-Parts-Accessories__ARM-VALVE-ROCKER-CAMSHAFT-HONDA-XR250-XR250L-XR250R_W0QQitemZ140299362141QQadiZ2863QQadnZMotorcycleQ20PartsQ20Q26Q20AccessoriesQQcmdZViewItemQQptZMotorcycles_Parts_Accessories?hash=item140299362141&_trksid=p4506.c0.m245&_trkparms=72%3A543%7C65%3A12%7C39%3A1%7C240%3A1318

    Camshaft and rockers all for $129.99 with free shipping...something tells me to steer clear from this, but at the same time I just don't know.... Has anyone here used one of these packages with success?
    #10
  11. Olas

    Olas the darkness

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    Scratch that idea above...I'm going OEM.

    I was looking at the flywheel puller for the XR250 and all it is is a bolt. 22mm x 1.5. Would a high quality bolt of the same specs from the hardware store do the trick or is there something special about these "flywheel pullers" that i'm not seeing?

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    #11
  12. wrk2surf

    wrk2surf on the gas or brakes

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    were there valve guide seals on the top end when you removed it?? Just sayin because I doin a rebuild and when I got the head serviced they lost the seals and said nothing. And I was thinking doing this what if someone wasnt up to par and rebuilt with no valve seals?? but my ktm has rubber c clip type.
    #12
  13. Mercury264

    Mercury264 Once you go Triple...

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    :lurk
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  14. Olas

    Olas the darkness

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    Yeah, the seals, valves and springs all came in a bag...

    I received the service manual today so i'll be able to start measuring parts soon, this weekend probably. Also expecting the complete engine gasket and oil seal set from Moose today. I can't wait to get started on this thing, it's going to be fun....i'll make it a point to take lots of good pictures as I go along.
    #14
  15. Reposado1800

    Reposado1800 Juicy J fan!

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    I wouldn't use a regular bolt for that application. That puller is most likely hardened so it won't deform under pressure. If you don't want to buy the puller, drop down by the bike shop and have them pull it off for you. It could be cheaper as they have the tool on the shelf.
    #15
  16. Olas

    Olas the darkness

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    Point taken, thanks.
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  17. Olas

    Olas the darkness

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    Guys, i'm not sure what to do here. Need some input. The cylinder "looks" to me like it could just be honed and another (new) 76mm piston be fitted. Not too sure though, i'd have to take it to the shop and have them tell me. Though, i'm wondering also if I should just buy a 77mm piston and have them bore it over 1mm. I'm even contemplating buying a new sleeve and starting at 74So, here are my questions:

    How big can you go with these stock sleeves? I see you can buy pistons up to 78mm. Is the sleeve prone to any damage being bored out so much? Will I have to modify my gaskets (Moose complete engine kit) to fit a 77mm piston?

    So many options to choose from, I may be leaning towards a 77mm piston more than the others though. Thoughts on this?

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    #17
  18. johnnyandjebus

    johnnyandjebus Been here awhile

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    I may not be able to contribute anything useful to the technical knowledge here, but I sure can :lurk like a pro! :D :clap


    What he said, looks like a great project!!
    #18
  19. Olas

    Olas the darkness

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    Well, to get the ball rolling, I ordered this:

    <TABLE cellSpacing=2 cellPadding=4 width="100%" border=0><TBODY><TR class=sectiontableentry1 vAlign=top><TD>XRs Only Piston Kit - Honda XR250R - 76.5mm / 10:5.1 / 272cc
    COATING: Standard Coating</TD><TD>XRPK-0272</TD><TD align=right>$189.95</TD><TD>1</TD><TD align=right>$189.95</TD></TR><TR class=sectiontableentry2 vAlign=top><TD>K&L Supply Cam / Timing Chains - Honda XR250 (86-95)
    </TD><TD>KL-120250</TD><TD align=right>$79.95</TD><TD>1</TD><TD align=right>$79.95</TD></TR><TR class=sectiontableentry1 vAlign=top><TD>K&L Supply Flywheel Puller - 22mm X 1.5mm RH Internal - Honda XR250R XR350R XR500R XR600R XR650L
    </TD><TD>KL-35-5944</TD><TD align=right>$20.93</TD><TD>1</TD><TD align=right>$20.93</TD></TR></TBODY></TABLE>
    Once I get the piston, i'll be able to take the barrel to the machine shop. While that's getting done I plan on splitting the cases for some general inspection. Pictures will be comming....

    Now, common sense tells me to replace the chain tensioner while i'm in there. I haven't looked at it closely but I looked at the guide and it looked "ok". Whaddaya say?
    #19
  20. apex

    apex /////

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    thats gonna be a nice bike! I used that same wiseco in my 250R, you will notice it makes more noise (piston slap) right away but Ive put over 5000 mi on mine since installing it. if the spring in the tensioner is still up to par Id reuse it.
    #20