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Old 09-20-2011, 06:42 AM   #796
chilibizkit
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G'day

Happy new owner of a 97 XR250R, which is going to be my winter project.

Can anyone help me out and suggest specific tools needed for a complete tear down except for the engine. Want to have the frame painted.

And yes this will be my first bike rebuild so will be taking lots of pics to aid rebuild

Thanks

chilibizkit screwed with this post 09-20-2011 at 08:29 AM
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Old 09-20-2011, 11:15 AM   #797
sion
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Quote:
Originally Posted by chilibizkit View Post
G'day

Happy new owner of a 97 XR250R, which is going to be my winter project.

Can anyone help me out and suggest specific tools needed for a complete tear down except for the engine. Want to have the frame painted.

And yes this will be my first bike rebuild so will be taking lots of pics to aid rebuild

Thanks
99% of the fasteners require either an 8, 10, 12 or 14 mm wrench/socket. Those and a flathead and philipshead screwdriver are about all you'll need if you aren't getting into the engine.
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Old 09-20-2011, 02:30 PM   #798
beat
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Quote:
Originally Posted by sion View Post
99% of the fasteners require either an 8, 10, 12 or 14 mm wrench/socket. Those and a flathead and philipshead screwdriver are about all you'll need if you aren't getting into the engine.
i think you also need 17 19 and 24 mm spanners (rear axle, swing arm-bolt), but i'm not certain. i've only done that with my xr4
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Old 09-20-2011, 05:12 PM   #799
chilibizkit
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Thanks for the info on tools, long as nothing honda specific I should be all set then.
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Old 09-21-2011, 09:05 AM   #800
beat
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Quote:
Originally Posted by chilibizkit View Post
Thanks for the info on tools, long as nothing honda specific I should be all set then.
you only need a M20x1.5 tread to pull the flywheel off
the rest is just metric

sorry that goes for the 400
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Old 09-22-2011, 02:09 AM   #801
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Do anyone know if it's possible to install the oil cooler from an XR400R on a XR250R? what's needed (appart from the oil cooler)?
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Old 09-22-2011, 08:52 PM   #802
Kestrel
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I figured I'd throw a post in here to hopefully catch the eyes of a few more ADV posters... I'm currently rebuilding my '94 XR250L, as seen in this thread... http://www.advrider.com/forums/showthread.php?t=726128

Took the valves out of the head tonight and discovered that it is perhaps in a lot worse condition than I anticipated. Seems like there's a hole in the valve seats... Photos here.





Do you guys think this head is trashed, or salvageable? Carbon buildup is pretty bad, and needs to be brushed out... But it is the top right valve seat in those photos that I'm worried about. There are also some cavities in the surrounding area. I've got not idea what happened to this bike; discovered one too many surprises from the previous owner. 'Project' indeed. Any advice would be appreciated - thanks again.
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Old 09-23-2011, 04:28 AM   #803
chilibizkit
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Now an unhappy owner of a XR250R,

Stripped down the bike last night and found couple of cracks and previous repair to the frame that couldn't see when all the bits were on.

Not liking the looks of things so now looking for a frame.

Doesn't have to be a 97 frame, any thoughts as to what can/could work for the shock and motor. At this point I don't even care if it's a Honda frame.

Thanks
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Old 09-23-2011, 10:27 AM   #804
beat
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Quote:
Originally Posted by chilibizkit View Post
Now an unhappy owner of a XR250R,

Stripped down the bike last night and found couple of cracks and previous repair to the frame that couldn't see when all the bits were on.

Not liking the looks of things so now looking for a frame.

Doesn't have to be a 97 frame, any thoughts as to what can/could work for the shock and motor. At this point I don't even care if it's a Honda frame.

Thanks
pic's?
cracks at the sidestand?
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Old 09-23-2011, 10:30 AM   #805
beat
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Quote:
Originally Posted by Kestrel View Post
Seems like there's a hole in the valve seats...
Do you guys think this head is trashed, or salvageable?
i thought valve seats can be replaces...
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Old 09-23-2011, 03:18 PM   #806
MentalGuru
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Quote:
Originally Posted by beat View Post
pic's?
cracks at the sidestand?
Post up pics please.

I had a friend haul my '87 XR250R and he only tied down the front and left the kickstand down. The bike hopped over to the right and bounced up and down on the kickstand enough to crack its mount.

I also have a XR650L and the frames are very close to being the same. The 650L frame has some reinforcements that the 250R frame doesn't. I will be adding them to the 250R frame.

Here is a picture of my XR250R. It has grown up...





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Old 10-03-2011, 09:36 AM   #807
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Ok, so I've begun the rebuild on my XR250R but I need to split the case to make sure I've got all the pieces of the damaged piston out. In order to do that I need to remove both the clutch and the flywheel. I got the clutch out but need a flywheel puller tool...or if I knew the thread size and pitch I can probably find a bolt at work that would do the trick.

anyone got a flywheel puller for small Honda engines that I can borrow?

or know what size the thread is?
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Old 10-03-2011, 01:40 PM   #808
beat
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my supplier got the flywheel puller from www.bikeservice.com.tw

i heard rumours that the rear axle bolt fits as a flywheel puller on the smaller single cylinder honda's...
but i didn't pull the 250 that far apart jet.
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Old 10-03-2011, 10:04 PM   #809
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so, the esteemed master of all things XR, inmate ValveCrusher kindly took time out of his day to inform me that I didn't really need to remove the flywheel in order to separate the cases. As long as I don't want/need to remove the crankshaft (I don't) then the flywheel can stay.

so I looked everything over carefully, decided he was probably right and went ahead the did the deed.

so far so good. I've got Dora tore down to (almost) the last bolt and nut.

got all the shrapnel of the bad piston out.

found a bearing that needs replacing, so, as soon as I can source that, I'll begin reassembly.
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Old 10-04-2011, 07:36 PM   #810
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ordered the bearing today, should be in next week, maybe as soon as friday...of course, it would just HAVE to be the oddball of all the engine bearings (17x42x12mm) and therefore no one stocks it.

anyway, I took the bad bearing, the damaged piston and wrist pin and made a little piece of "art" to stick on the shelf:





a little tribute to my own stupidity...to keep me humble
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