Hillbilly XL250s Resto

[Weldangrind]

Not meant to imply a factory-correct resto, just trying to clean up a nasty old bike. A while back, Son of Weldangrind and I traded our '78 MX175 for an '81 XL250S (plus cash :D ). This bike was really rough, but it started on the first kick and didn't smoke or make ugly noises. I originally planned to obtain the title and ride it on the street, but I have other plans. I'm just cleaning this bike up for sale now.

Here's the ugly bike when we brought it home:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/IMG00240-20110407-1932.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=IMG00240-20110407-1932.jpg)

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/IMG00241-20110407-1932.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=IMG00241-20110407-1932.jpg)

I picked up antother XL250S a couple of weeks later in even worse shape, but it was nearly free and had some good parts. The tank was not quite as bad as the one pictured, but it was rusted through in one spot. I ground out the rust, hammered it in and filled it with Permatex Cold Weld. I didn't use JB weld because it doesn't actually say that it resists gasoline.

I picked the best exhaust header out of the two (which was still very rusty) and tried the electrolytic de-rusting trick on it. Wow! It really works. for those who aren't familiar, you fill a large plastic container with warm water, add some Arm & Hammer washing soda and stir it up. Place a large piece of clean steel (ideally larger than your rusty part) in the water and connect the positive clamp from your battery charger to it. Connect the negative clamp to the rusty piece, put it in the water and plug the battery charger in. Ten minutes later, this was the result:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06012.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06012.jpg)

One shock bushing was beat to death, so I popped the metal sleeve out and removed what was left of the rubber. A quick measurement revealed that 5/8" heater hose is a good match.

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06014.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06014.jpg)

I pressed the metal sleeve into the heater hose and called it done.

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06015.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06015.jpg)

This is the assembled bushing next to the wasted one:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06018.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06018.jpg)

The muffler was a rotten mess. I cut off the offending garbage and bought a piece of exhaust tubing to weld on. Welding rusty metal is no fun, but it stuck. Here's the mock-up:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06022.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06022.jpg)


I used a leftover from a Beast ATV muffler for the exit pipe, because it will act as a spark arrestor without compromising flow too badly. I cut a disc out of some plate and ground a hole in the middle to match the exit pipe:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06020.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06020.jpg)

I then welded the disc into the exhaust tubing and then welded the original bracket in place:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06025.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06025.jpg)

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06026.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06026.jpg)

This is the muffler after some heat paint:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06027.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06027.jpg)

I filled the dents in the tank, painted it with Krylon Fusion Red Pepper (might as well be called Honda Red), recovered the seat with an eBay score and painted the fenders and side panels with Krylon Fusion. This is the result so far, with many parts left to reassemble:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06024.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06024.jpg)

The brake pedal and footpeg assembly was terribly bent, as were the handlebars. After much heating and bending, those parts are looking more respectable and will go on the bike after some paint.

More to follow as I find time.

[Weldangrind]

Forgot to mention that I also painted the rusty coil springs and swingarm. The swingarm is now battleship grey, because that's what I had laying around. It'll do. I put a used 18" rear tire on to replace the rubber band that came with the bike. The 30 year old (!) front tire is in remarkably good shape, and I'm not buying a new one. They're oddball at 23".

[FastDoc]

You impress me to no end, Weld. I am envious of your project! Will it be street legal? Have you picked out a name yet? :P

[MICRider]

I like it! Nice to see another old Honda coming back from the dead :). I'm really interested in the electrolytic metal cleaning process... Did it remove all the old paint as well as the rust? It almost looks sandblasted! Also, what do you set your charger at? 12volt 10 amps? The clean piece of steel, you just mean a piece with no rust on it? Carbon steel? Thanky for the info, I'd heard of this before but this was the first time I'd seen the results, very impressed! :D

[katoranger]

I think that DogofWeld is getting ready to do some business.


Thanks for the info on the electro process.

[Weldangrind]

You impress me to no end, Weld. I am envious of your project! Will it be street legal? Have you picked out a name yet? :P

Thanks Doc. :)

I have my eye on another bike right now, and the XL is an '81 with twin shocks and a 6 volt system. From everything I've read online, the 6 volt headlight has all the lumen quality of a candle, and I'm not going to spend the time / money to convert it. If I was to ride an old XL on the street, I would prefer an '82 or later.

Haven't thought of a name. Perhaps Polished Turd?

[Weldangrind]

I like it! Nice to see another old Honda coming back from the dead :). I'm really interested in the electrolytic metal cleaning process... Did it remove all the old paint as well as the rust? It almost looks sandblasted! Also, what do you set your charger at? 12volt 10 amps? The clean piece of steel, you just mean a piece with no rust on it? Carbon steel? Thanky for the info, I'd heard of this before but this was the first time I'd seen the results, very impressed! :D

I was really impressed as well. Another thing to consider is that the process might have been even faster than I realized; perhaps it was clean inside of 10 minutes.

There wasn't any paint on the part to remove, but I don't think that paint would be removed if the metal under it is sound. Anywhere that rust exists will be converted to what I presume to be a phosphate coating. It simply wipes / brushes off. I happened to have the charger set to 12 / 10, but I don't think it needs more than one amp. I just used a piece of steel plate that wasn't terribly rusty, and it becomes the sacrificial anode (perhaps cathode in this case?). I intend to grind the new rust off of it and use it again.

I searched all over for Arm & Hammer washing soda, but it's not common in Canada. I bought a box at Walmart in Washington State, but I've since heard that it's available at London Drugs.

[Weldangrind]

I think that DogofWeld is getting ready to do some business.


Thanks for the info on the electro process.

That's Cooper the Shop Dog struggling to get up after a nap in the sun. He has a designated area in the back yard that is referred to as Poo Corner, and he doesn't violate any other area. He's a good boy. :lol:

You're welcome. Let me know if you need any other details about the process. I'll add that the mix ratio was 1 tbsp per gallon of warm water; apparently any more than that is a waste.

[katoranger]

Thanks. I am going to have to give is try on some tractor parts. Looks alot easier than sanding off rust.

[Jim]

Cool project, I quite like how the de-rusting worked out :)

[SpudRider]

Wow! You did a superb job on the muffler; it looks great! :) Thanks for the information on the derusting!

Spud :)

[Weldangrind]

Thanks guys! I'm interested to hear how the hillbilly muffler sounds.

[Weldangrind]

More to report tonight. I straightened the terribly bent brake pedal and modified a bushing for it. A 5/8" OD bushing is a perfect fit into the pedal, but the ID won't slip over the unique bolt. I ground the ID of the bushing with a Dremel and an abrasive bit, per TurboT's instructions. It worked perfectly. This is the pedal and bushing:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06029.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06029.jpg)

See the bent lever on the right? The one on the left was even worse, but it straightened out nicely with some heat, bending, pounding and intimidation. I had to weld the toe piece where it cracked, but it'll be fine.

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06031.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06031.jpg)

Since I had drained the oil, I decided to remove the right side cover to gain access to the oil filter. I'm really glad that Honda came to their senses and redesigned the filter with easier access. This is the side cover:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06032.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06032.jpg)

This is the inside of the cover upon removal. I'm pleased with how clean it is.

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06035.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06035.jpg)

Here's what hides behind the cover. You have to go this far to remove the oil filter. :roll:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06034.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06034.jpg)

This is where the filter lives.

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06036.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06036.jpg)

It looks really good.

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06037.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06037.jpg)

While you have the cover off, it's an excellent opportunity to adjust the counterweight chain tension. This shot shows the tensioner before adjustment:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06038.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06038.jpg)

Once you loosen the bolt, the flange is pulled by the spring to this position:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06040.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06040.jpg)

The manual then directs you to move the flange one notch in a clockwise direction and tighten the bolt to 22 ft/lbs. Here's the final adjustment:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06041.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06041.jpg)

I don't think that cover has ever been off, but the inside looks really good. Somebody will get many happy miles from this bike.

I also mounted the air box and rear fenders and I painted the footpeg mounts. More to come!

[SpudRider]

What a great thread! The engine looks very clean. :) Was the oil screen that clean also, or did you clean it up a bit before you took the photograph?

Spud :)

[Jim]

Great project :) Definitely cleaner inside then my Honda :lol:

[Weldangrind]

What a great thread! The engine looks very clean. :) Was the oil screen that clean also, or did you clean it up a bit before you took the photograph?

Spud :)

Thanks Spud. :D

That's exactly how the screen came out. I wiped it off after and blew it out with the compressor, but it wasn't at all dirty.

[Weldangrind]

Great project :) Definitely cleaner inside then my Honda :lol:

I'm shocked at how clean it is. Look at the pics from when I brought it home, and you can guess what I thought the filter would look like.

[SpudRider]

What a great thread! The engine looks very clean. :) Was the oil screen that clean also, or did you clean it up a bit before you took the photograph?

Spud :)

Thanks Spud. :D

That's exactly how the screen came out. I wiped it off after and blew it out with the compressor, but it wasn't at all dirty.
My goodness! The engine appears to be in wonderful condition! :D

Spud :)

[Weldangrind]

A little more progress. Got the header and heat shields installed, along with the right footpeg and brake pedal. It's slowly coming together.

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06043.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06043.jpg)

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06044.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06044.jpg)

[MICRider]

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06043.jpg

Is that a decompression device at the top of the cylinder head? I see the cable running down from it. If it is, is it actuated by the kickstarter? I just can't see where it connects on the bottom?

[Weldangrind]

Yep, automatic decompressor, and it's a work of art. You don't even have to stand up to kick it over, and it usually starts first kick. Gotta love old Hondas.

Look at the second pic above, and you'll see the end of the cable just above the kicker pivot. Need a more close-up pic?

[MICRider]

Yep, automatic decompressor, and it's a work of art. You don't even have to stand up to kick it over, and it usually starts first kick. Gotta love old Hondas.

Look at the second pic above, and you'll see the end of the cable just above the kicker pivot. Need a more close-up pic?

Ahh! I see where it hooks now, cool system! Have you ran it with the new muffler yet? I bet it sounds good! Speaking of the muffler, I know you mentioned it before but I cant remember, do you use flux core or gas?

[Weldangrind]

Haven't tried it yet; hopefully soon.

I use a MIG with 75/25 usually, but right now I'm using tri-mix. The trix-mix is connected because I welded some stainless the other day, and because I'm out of 75/25. It usually goes on sale at KMS in November, so I can wait.

[Weldangrind]

Got some more time on it after Church. I realized that I forgot to install the return spring for the brake pedal, so I did that first. Duh. I swapped on another fork leg that was in better shape, installed the front fender, seat, tank, bars, throttle, levers, kill switch and side panels. I've yet to put the pegs and fuel line on, but that won't take long. Here's what it's shaping up to be:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06046.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06046.jpg)

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06048.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06048.jpg)

[Jim]

Wow, that's looking very good :)

[Weldangrind]

Thanks. To me, it's better than this:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/IMG00241-20110407-1932.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=IMG00241-20110407-1932.jpg)

[FastDoc]

AMAZING RESULT! :P

[MICRider]

Looks great! Huge (as in REALLY) huge improvement! :) You said your building this one to sell?

[Weldangrind]

Looks great! Huge (as in REALLY) huge improvement! :) You said your building this one to sell?

Yeah, I just delighted in this project. I'd be happy to sell it for much less to a China Rider brother than a CL buyer.

Thanks for the comments, guys. :D

[SpudRider]

That's an amazing transformation. You do beautiful work. :) Did you get new plastic, new fenders, and a new fuel tank, or did you paint the old ones? Did you buy the decals from eBay?

Spud :)

[Weldangrind]

Thanks Spud. :D

The front fender was donated by Son of Weldangrind's XR200R, since that bike now has a CR125 fender that is in much better shape. Both fenders and side covers were covered with poorly applied black spray paint, and it was a chore to clean them properly. I've learned that the most efficient way is to soak a rag in laquer thinner and drape it over the plastic for a couple of minutes; upon removing the rag, the paint is bubbled and wipes right off.

Once I got the old paint off, I repaired the plastic as necessary and sanded it to where it was (relatively) smooth. I then painted the plastic with Krylon Fusion Red Pepper, which is a very good choice for a Honda. Since Krylon Fusion can also be used on metal, I painted the tank with it.

The tank had some serious dents that I popped out with air pressure and various pieces of steel, than I filled in the remaining large dents with fiberglass and then Bondo. There are a few smaller dents in the tank still, but I'm not worried about them.

In this case, finished is better than perfect. I hope that someone enjoys this bike for what it is.

[FastDoc]

I'd buy that in a heartbeat! Why sell it? I regrest selling my Dirt Rat and it wasn't even street legal. Is it the rear suspension?

[katoranger]

It looks good. Will make someone a nice trail bike.

[Weldangrind]

I'd buy that in a heartbeat! Why sell it? I regrest selling my Dirt Rat and it wasn't even street legal. Is it the rear suspension?

It's not what I want. I picked it (and a parts bike) for a song, otherwise I wouldn't have bothered. I was looking for a bike that I could put on the street, and that would entail a complete wiring harness, lights and a horn. While that's certainly possible, the stock setup is 6 volts, and the headlights are renowned for being quite dim. I could change it to 12 volt with an '82 stator, but they're like gold on eBay. The '82 would be ideal, especially since they were the first year of the Pro-Link for the street.

Instead, I found another project. :D

I don't need this bike for off-road riding, because I still have my '96 XR250R, which I love. I resurrected that one a few years ago. Son of Weldangrind has his Dirt Rat, and we have enough junk to build an early XR200 twin shock buddy bike. We have no need for this XL250S, but we do need the space.

[SpudRider]

Thanks Spud. :D

The front fender was donated by Son of Weldangrind's XR200R, since that bike now has a CR125 fender that is in much better shape. Both fenders and side covers were covered with poorly applied black spray paint, and it was a chore to clean them properly. I've learned that the most efficient way is to soak a rag in laquer thinner and drape it over the plastic for a couple of minutes; upon removing the rag, the paint is bubbled and wipes right off.

Once I got the old paint off, I repaired the plastic as necessary and sanded it to where it was (relatively) smooth. I then painted the plastic with Krylon Fusion Red Pepper, which is a very good choice for a Honda. Since Krylon Fusion can also be used on metal, I painted the tank with it.

The tank had some serious dents that I popped out with air pressure and various pieces of steel, than I filled in the remaining large dents with fiberglass and then Bondo. There are a few smaller dents in the tank still, but I'm not worried about them.

In this case, finished is better than perfect. I hope that someone enjoys this bike for what it is.
You did a beautiful job on this bike, Weld! :D Indeed, the Kryon Fusion, Red Pepper paint is essentially Honda Red. ;) I agree with the others; since the engine is in such good condition, I think you should consider keeping this bike! :)

Spud :)

[Weldangrind]

I finished it today. I cleaned and installed two decent foot pegs and springs and installed a new fuel line. I also took the nasty chain out of the bucket (where it had been soaking in Varsol for a week) and cleaned it on the bench grinder wire wheel. The chain got a good dose of Chain Wax, and it looks presentable now.

I put some gas in it, pulled the choke knob and kicked it over. Click the pic to play a short video. That's all I got before the camera battery died.

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/th_MOV06053.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=MOV06053.mp4)

After it warmed up, I adjusted the timing chain tension and took it for a victory lap in the cul-de-sac across the street. The hillbilly muffler sounds pretty good. :D

[FastDoc]

Sounds like a Honda.

Sounds great. 8)

[SpudRider]

The muffler sounds great! :D

Spud :)

[Weldangrind]

Thanks! TurboT hopes that my welds don't fail under the exhaust pressure. :lol:

[MICRider]

Love it! Purrs like a kitten :)

[Weldangrind]

Son of Weldangrind took a victory lap yesterday. Click the pic to watch.

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/th_MOV06078.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=MOV06078.mp4)

[SpudRider]

The bike seems to run great! I can't get over how good that muffler sounds! :D

Spud :)

[Weldangrind]

Thanks again! :D The heat paint on the header smokes a bit, but that'll burn off eventually. It hasn't had more than five minutes of run time since it's been back together.

[Weldangrind]

Sold 'er tonight. Got a good price, and it went to a fine young man who was originally from Saskatoon. I'm sure it went to a good home. Here's a couple of shots that I posted in the ad:

http://i158.photobucket.com/albums/t109/Weldangrind/For%20Sale/DSC06099.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/For%20Sale/?action=view&current=DSC06099.jpg)

http://i158.photobucket.com/albums/t109/Weldangrind/For%20Sale/DSC06100.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/For%20Sale/?action=view&current=DSC06100.jpg)

[Jim]

Looks great :)

[SpudRider]

The bike looks great! I hope the young man enjoys his "new" ride. :D

Spud :)

[Weldangrind]

Thanks guys. :D

Now to concentrate on the TS185 and TW200 (followed by another project). :wink:

[FastDoc]

Well done. It feels good to sell a good bike at a good price to a good person. Now you'll be able to enjoy, and finance the other projects better.

Great sales pic, BTW. :wink:

[SpudRider]

Well done. It feels good to sell a good bike at a good price to a good person. Now you'll be able to enjoy, and finance the other projects better.

Great sales pic, BTW. :wink:
Indeed! Your "for sale" photographs were superb, Weld. :D

Spud :)

[Weldangrind]

Thanks.

There were others, but I didn't post the blurry ones here. :lol: