1985 DR250S rebuild, and garage fun in Tassie.

Discussion in 'Some Assembly Required' started by sruss67, Jul 6, 2020.

  1. Franque

    Franque Nilé na sohakélwa manga

    Joined:
    Apr 26, 2015
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    Marseille, France -> Dakar, Sénégal
    Looking good! I've got an '81 that's going to be a quick budget build in a couple of weeks. Mine's gone full Chinese though, I've got a pushrod/e-start 200 5-speed going in.
  2. sruss67

    sruss67 Been here awhile Supporter

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    81 XR200, the original Franque?
    I noticed many Chinese parts online for the XR range.
  3. Franque

    Franque Nilé na sohakélwa manga

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    It's the XR200R with the prolink, like you're looking for. I wouldn't mind doing a restoration, but this one's going to be quick and dirty so I have something to ride when I'm in the States, and I also bought it as a stripped rolling chassis so there won't be too much in the way of originality.

    Most of the cheap Chinese bikes with the vertical motors are based on the twinshock versions, but converted to monoshock, usually without a linkage for the rear shock.

    Some stuff crosses over, but these are somewhat oddballs when it comes to Hondas, the 81-83 Rs and the 83-84 XL200Rs are somewhat similar, but there wasn't anything else that was much like them in terms of Hondas sold in the US, so you're really better off with a twinshock if you want to use Chinese parts, and there's more Honda parts availability for the twinshockers.

    I've done a fair bit of research, and know a bit about them, so let me know if you have any questions/need advice or sources.
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  4. tinwelp

    tinwelp Professional Idiot

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    Russ... check the threads on the exhaust ports... top right as shown (first picture) doesn't look correct.
    Tiny ports!

    Cheers... Paul
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  5. sruss67

    sruss67 Been here awhile Supporter

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    Franque, thanks for the info, will keep you in mind if I get stuck with anything.
    I found plenty of great info at thumpertalk forum and xronly web page.
    Will be restoring and modifying the XR somewhat as I would like an aluminium swingarm and a disc front end.

    tinwelp, I will check the threads, and need to remove the cover from the crankshaft to check everything in the head.
    Yep, the exhaust ports are tiny.
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  6. sruss67

    sruss67 Been here awhile Supporter

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    Paul, all threads are spot on, it was the angle and blur in the photo that made the threads look out of whack.

    Disassembled the head yesterday to inspect the parts and see what the quality was like.
    Must say I am very happy and all looks great.

    IMG_20210807_150943.jpg IMG_20210807_151013.jpg

    Waiting on the cylinder and piston kit, a couple of small parts and a new clutch kit then it is time to reassemble and get her running again :rayof
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  7. Franque

    Franque Nilé na sohakélwa manga

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    Make sure to lap the valves in place while you've got it apart! It looks great!
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  8. sruss67

    sruss67 Been here awhile Supporter

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    The cylinder and piston kit arrived and looks to be very good also.

    Now to find time to reassemble and get the old girl going again :-)
    IMG_20210821_131602.jpg IMG_20210821_131642.jpg IMG_20210821_131650.jpg IMG_20210821_131711.jpg IMG_20210821_131755.jpg IMG_20210821_131803.jpg
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  9. sruss67

    sruss67 Been here awhile Supporter

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    Started to assemble the new parts yesterday.
    Using assembly lube from Penrite in place of the moly lube suggested by Suzuki.
    Fitted the piston and rings, the new gasket and the dowels.
    Next up is the cylinder.
    IMG_20210825_164145.jpg IMG_20210825_164150.jpg IMG_20210825_165108.jpg IMG_20210825_165118.jpg
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  10. tinwelp

    tinwelp Professional Idiot

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    It's unusual to see the piston valve reliefs like that... usually the inlet side are the larger ones. Much depends on the engine design and valve timing of course, but it's odd to see, especially when the 'point forward arrow' is obviously correct. Was the OE piston like that?

    It'll be great to hear this running again. I've a big soft spot for 4st tiddlers like this.

    Carry on Sir!

    Cheers... Paul
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  11. sruss67

    sruss67 Been here awhile Supporter

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    Thanks Paul, the piston valve reliefs match the factory Suzuki piston exactly.
    I was quite surprised to see this also when removing the original.
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  12. sruss67

    sruss67 Been here awhile Supporter

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    A little more assembly this afternoon with the cylinder and head going on.

    IMG_20210827_170030.jpg IMG_20210827_170035.jpg IMG_20210827_170040.jpg IMG_20210827_170141.jpg

    Hopefully get some time over the weekend to assemble and check everything.
    Going together nicely for my first rebuild :happay
  13. mentolio

    mentolio King of the island of unwanted toys...

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    Looking good! I recently rebuilt my 250 top end (March or April?) and it is amazing to me how much better it runs. I thought it was pretty good before…it definitely was NOT. Simply not burning a bunch of oil makes so much difference. I am excited for you, and look forward to reading about the finished product.
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  14. sruss67

    sruss67 Been here awhile Supporter

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    Thanks Mentolio, excited to get her together again and see the difference from the seat of pants experience. Should be good.
  15. sruss67

    sruss67 Been here awhile Supporter

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    Got the head on and torqued down, camshaft in and chain on.
    IMG_20210828_172844.jpg IMG_20210828_172853.jpg IMG_20210828_172902.jpg
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  16. nostep

    nostep Been here awhile

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    Looking good!

    I have yet to do a rebuild, although I'm sure I will some day.
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  17. sruss67

    sruss67 Been here awhile Supporter

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    Got a heap more done today :-)
    IMG_20210904_134033.jpg

    Found one of my spoke keys from the bicycle industry fits the valve bolt perfectly.
    It is a square drive for Fulcrum and possibly Giant spokes in 14g from memory.
    It made the valve adjustments much easier.

    IMG_20210904_152146.jpg

    Got the replacement clutch plates and steels fitted.
    The originals were right at their limit so worth replacing whilst apart.

    IMG_20210904_170817.jpg

    And managed to get the engine, carby, airbox and chain installed.
    Getting closer to the initial start after the rebuild :-)

    IMG_20210904_170828.jpg
  18. sruss67

    sruss67 Been here awhile Supporter

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    So yesterday I got everything together and attempted to start the bike, she would fire but not start.
    Got to thinking about the valves and timing and reckon I have the timing out by 180deg :asshat
    The reason I came to this conclusion is when I set the camshaft at what I thought was TDC, and aligned everything spot on, the valves were closed on the exhaust side once I had fitted the head cover and went to adjust the gaps :loco

    So then I moved the TDC mark another rotation to allow movement at both inlet and exhaust valves, without even thinking about the fact that this would have moved the cam around also :baldy

    Chalk it up as a learning experience :jack
    Now I am hoping I have enough room with the tank off to remove the head cover and move the cam under the cam chain and then recheck the valve clearances, if not I will be removing the engine yet again.
  19. sruss67

    sruss67 Been here awhile Supporter

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    IMG_20210904_170817.jpg
    IMG_20210904_170828.jpg IMG_20210905_112815.jpg
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  20. mentolio

    mentolio King of the island of unwanted toys...

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    Last picture tank is back on…does that mean “it..is..ALIVE” ???
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