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Honda XL250 MOTOSPORT 250 K0 US Forum


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1973 Project bike

- Honda XL250 MOTOSPORT 250 K0 US Forum

Author Message
Alex Bringhurst
Posts: 4
Posted: Friday, February 27, 2009 16:26 

Subject: 1973 Project bike

I was given this bike from a friend at work.
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He had owned it since it was purcahsed new in '73. A year ago it was sold to his neighbor. The clutch went out on it and so the bike ended up in my hands. I thought the bike was in overall good condition so I was curious to see what could be done with her. First order of business was to repair the clutch rod pivot bearing. This picture doesn't quite show it, but the original needle bearing had rusted and failed, thus causing the clutch to stick.
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It wasn't too difficult changing the bearing and now it works nicely. With the clutch working, I filled her with oil (she was bone dry) and fresh fuel and took her for a spin around the block. She did run nicely. With the clutch working well and her running, I wanted to adjust the valves since this bike had almost 10,000 miles and they probably had never been adjusted. Once I removed the valve covers and realized there was quite a bit of cooked oil saturated with metal flakes. This prompted me to fully remove the cam cover. Much as I suspected, the cam was shot along with the bearings in the cam cover and head.
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I fairly certain the cause of the failure was that since the bike had at one time been drained of oil, some sludge like residue had clogged the oil ports for the cam bearings. So, I tore down the whole top end. The cylinder appeared to have only a few scratches, nothing too bad. The piston skirt did show some wear and the dome was caked with carbon. It's amazing that she ran as nicely as she did, even with all these problems.

The solution: I have shipped the cylinder, head and cam cover to Dave at xlintperformance.com He is going to line bore the head and cam cover to allow them to accept a new cam that will have needle bearings. By far a superior method. Plus, I still get to use my head and cam cover which I thought were headed to the recycling bin. In addition, he will perform a valve job and bore the cylinder. We'll install a new overbored high compression stock-sized piston.

I do like this bike a lot. I'm excited to get her running right again and fix the other things that plague her. Should be fun posting her progress on here, so check back and we'll see how it goes.  reply to this

Fast Eddie
Posts: 168
Posted: Tuesday, March 3, 2009 16:22 

Subject: Re: 1973 Project bike

Excellent post Alex!

I look forward to your next updates.   reply to this
"I Get From Zero To horny In Just 2.56 Beers""
Alex Bringhurst
Posts: 4
Posted: Wednesday, March 11, 2009 04:42 

Subject: Re: Re: 1973 Project bike

Well, I think I may have gone overboard. Since I have to wait for the head to get line bored, I decided to "fix" things up a little. So, I completely disassembled the bike.

Here are the frame components after it was stripped naked.
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I took them to Jim at East Idaho Powder Coating and let him work his magic. After a good sandblasting and a powder coat, here's how they turned out:
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My photo skills don't do it justice. It simply looks amazing. The shine and finish are awesome. Makes me want to powder coat everything!

While I had the motor out, I tore into it. As you can see in this first picture, there was some serious sludge that ultimately caused the cam failure. you can see how that would clog the small oil holes that lubricate the cam bearings. This is a view of what was in the lower case half right after I took it apart:
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With the case empty, you can see how dirty it was:
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So, my buddy at Snow and Dirt did the beadblasting for me and got her looking nice and clean:
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And here's the insides after a good soaking:
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So, next up... All the new seals and gaskets for the motor should be here soon. With those, we'll button up the lower engine half. The frame components are ready to begin being pieced back together as well. But wait, we have other projects in the work too:
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  reply to this
Alex Bringhurst
Posts: 4
Posted: Wednesday, March 11, 2009 04:50 

Subject: Re: 1973 Project bike

Apparently, I need to figure out this forum a little better... it's not the most user friendly but I think I'mn getting it. Anywho, sorry for the dounle post. The first post had a repeated picture in it, so I tried to edit it with the right one and it ended up posting the whole thing again, oops... sorry.   reply to this
Edwin Van Der Veen
Posts: 5
Posted: Monday, March 16, 2009 13:32 

Subject: Re: Re: 1973 Project bike

The double post has been removed.

Keep up the good work with this excellent thread!  reply to this
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