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1984 XR 250R-Restoration Project!

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So I've been meaning to start this up here on TT... For ages!!!

I've slowly started restoring an '84 XR 250 to like new. It's a hybrid restoration ( using some aftermarket bits ), but mostly original and following the same ideas by Honda ( colour schemes etc )

It's a long process and I have well over 300 plus progress picture so I'll update as I can... But here are some highlights pictures!! Hope you guys enjoy!!

This is what I started out with and only a few months ago I purchased a more complete donor bike....

C82F84C0-BF00-4E2E-91D4-772DBB88579C-730

It wasn't much but it got me going! :)

The motor was junk so I found another....

EC9A9F6D-122A-4BCA-A78B-A28A84DE36E4-730

I got the frame down and ready for new PC

40EF59E1-7F0C-431E-A300-C928282E62D8-136

This is the motor that I decided on... Stripped down and ready for restoration!!

231B44F2-9EEC-44E7-A427-7F0579E60B9F-220

7A5CF1BE-8615-4B1C-A5BF-94C4185B0B4B-220

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8760A3D2-8E2E-4FCB-841A-549233593853-164

Non cracked head!!!

F8DEF0A7-1645-4CF4-A0FB-48965F2FD19A-474

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Here are the carbs

979A053C-FE5D-49AF-A1E0-D1C31E5294BD-293

47886CB0-1CE4-4D7F-B93C-6C6A3A0EDAC8-293

No it's organised mess ;)

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These are the header pipes and done other misc parts that will be restored

1DC4A575-EC51-4C0F-8C5A-E74ECE97CEB3-136

Now I know what you might be thinking...... There is no way on earth this could ever amount to a bike.... Well .... :) just wait ;)

Various parts for PC in satin black....

D14AF506-9388-43E4-89B0-DA888602E06C-336

1ACEC4F7-DCD0-48C2-A322-74E8B9D1BE15-336

I liked the OEM look of the muffler so I searched for a restorable candidate....

95C4F8DB-B8B0-464C-AD20-3EDDBBD2FDD1-334

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Here are the forks before.....

D8E93FA9-76B0-4DCB-A6B2-CC3BFB926827_zps

The shock was a MESS!!!!

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No point reusing the spokes and all ......

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These are just snippets of the progress over the last little bit....

I will show some of the transformation pictures soon :D

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Cool cool, keep us updated!  I'd love a project bike for a CR 500 since I owned one in the mid 2000s, but with kids and a baby it's tough to find the me time.  Will be for several years.

Hey!! Thanks for the reply :) this should be a nice build ( might take a while ) I'm putting a lot of time into this one amount my various other projects .... It's actually coming together nicely!!

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Ok enough of the grotty old junk that I had to restore... Here are the labour fruits...

I'm certainly leaving nothing half done!!

First up ... Frame and misc parts from powder:

D6FF1F87-D979-4066-86CA-CACC62BF2469-944

1B6EA3A2-AA43-4E1E-8F55-6F20B00481DE-592

750C2C72-B474-4586-AFE0-E6AF30CD2E2E-592

6F45A563-DB66-4700-998B-D719D96A1D0E-944

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DE7A9EB9-624A-468B-90F3-5A4C24D727B3-944

The last picture really show the contrast and how well it works together !!

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Up next we have the restored header and muffler....

AA211BF1-60D2-4979-8DAB-FD5F3F0E5FE6-338

Yes that is the header you previously saw......... :D

57DCEE62-8734-4A4A-BC4B-8D84C26C79E4-338

Muffler in matching ...

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The complete system

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This is a modern OE match finish....

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C94E0A1E-E22D-4CE5-A9A6-D8DC3946E93C-758

Carb bodies before restoration...

F1501A48-2B78-4B5A-96F6-728E9513756B-649

:D don't fall off your chair now ;)

And misc parts now gold plate ...

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F4BC4F2B-7692-45E0-889A-44BD7541BB96-185

And after sourcing new rebuild parts, I now have virtually brand new carbs....

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4DB23FFB-EDEF-471D-8AAF-7B5B56B36FFF-207

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D439988E-4BFD-491D-9474-DA0448E9DC3E-207

:) I put a LOT of effort into these carbs but the results... Well pictures say a thousand words !!

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Remember that old engine........

Here you go.....

9A3810E7-996D-41EC-81FF-3AB0E39653E0-180

602D3E98-7F24-4140-B92C-55D1CFDE1A3F-575

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Absolutely BEAUTIFUL head, came out amazing !!

83C064E9-4D00-45C7-9909-BB59988973BD-575

CAC842DC-B64B-4D2C-A9F7-3B805AD23FED_zps

Ported and flowed it should be a real ripper!!!!

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Do tell how got some of the parts in such immaculate shape (ie the carbs) I am in the middle of the same project with an 84 xr 500 and I am watching your project closely so I am very interested to watch the whole thing unfold and any advise you post will be great and needed news.

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Hello all :)

I'm not sure how this whole thread is over a year old without any updates!?!?!? SO much has happened in the last year... A lot of life has gotten in the way and I'm much further along with the bike...

Since that last post I have assembled 80% of the frame! I'll update some pictures of the big parts :)

Spudman- I had all the metal parts electroplated with the gold plated ( I'm must warn you that the parts have to have a good surface finish BEFORE the plating otherwise the finish is never as good ).

The carb bodies got Aqua blasted. The best finish ( raw finish ) you can achieve.

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A30A04C4-81ED-46E1-A1F9-983732826C8D_zps

45D14526-16DC-428C-867A-CFA59A20FB09_zps

As you can see I decided to match the hub centres with the same flash red use for the frame... Turned out really good!!!

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Fork tubes ready for reassembly! I took my time restoring these and they are truely better than new!!!

3C32E14E-4304-45C3-83E6-0B3847BC7F7D_zps

The final product...

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42869F8F-8730-43C7-8918-33C58C233892_zps

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