Honda XL 250 1981

[Diggy]

Hello

Does anyone know anything about this bike. If you please do can you tell me a little about it. I was able to pick one up and I need to fix a couple things for it.

Thank you!

[Bruces]

They are a very good bike .What do you want to know ?

[Diggy]

I have a lot of question.

Gas tank has some dents in it and I would like to fix it. Anyone have experience in this?

The person told me runs good but needs a carb clean.

Anything I should know about the carb and should I buy anything for it?

Also I live in Canada I do want to get it on the road and I was thinking of moving everything g to LED. I do not know much about the 6V system. Could anyone help me with this?

Thank you

[OneLeggedRider]

Gas tank dents. A technique that can work on some is to gently heat the area with a hairdryer or heat gun ( the latter can blister paint or remove paint easily, so caution) Then apply ice to the dent. Often it will pop out with a loud pop due to the rapid contraction of the metal chilling. Works some of the time. You can also try a glue stick dent puller.

Don't try the old method of filling the tank with water and putting it in a freezer, about half the time it will split the tank at the lower seams.

Cleaning a carb is really simple, watch some YouTube videos.

[Bruces]

There is another member on this site rebuilding a Honda xl ,he is from Australia or New Zealand and his is an early 90’s model ,but it appears to be identical to the early 80’s models we had in North America .He is doing a great job and would be worth reading his thread .His name is Excelsior or something like that .
Where about in Canada are you from ?a few of us might be your neighbour !

[XLsior]

Hi Diggy, Bruces eluded to my XL185/CG250 swap project thread which you might find useful.

I am not sure how extensive the dents in the tank are or if you are trying to preserve original paint/patina but i just went cheap and used filler for small pea and peanut dings.

As for 6V LED... I don't believe there is as an extensive range of options. Most if not all modern stuff is 12V LED. But just try searching aliexpress or similar and with a bit of tinkering and DIY i think it could be done.

the RFVC engine is pretty bulletproof but I think your biggest issue might be trying to replace a 23" front tire if that is what it has equipped.

[Diggy]

There is another member on this site rebuilding a Honda xl ,he is from Australia or New Zealand and his is an early 90’s model ,but it appears to be identical to the early 80’s models we had in North America .He is doing a great job and would be worth reading his thread .His name is Excelsior or something like that .
Where about in Canada are you from ?a few of us might be your neighbour !

I just want to say thank you for the information! I will try to find Excelsior posts. I’m from Ontario! You?

[Diggy]

Thank you so much for the information on different ideas on how to fix the dent. I have one on the front and one on the left side. They are pretty but ig dents and may just pop back in place. Crossing fingers! Yes I will also look up YouTube videos on this carb. It should be pretty easy!

Any other info please let me know!

Thanks

[Diggy]

So I was looking at the muffler area around engine. Is there anything I can do to make this pipe better or protect it. I know they get very hot and most look like this?

Also I am kinda new on how to take care of the engine? What is the best thing to clean up the engine? I seen all these kind of sprays any tips?

Thank you

[Diggy]

So I was looking at the muffler area around engine. Is there anything I can do to make this pipe better or protect it. I know they get very hot and most look like this?

Also I am kinda new on how to take care of the engine? What is the best thing to clean up the engine? I seen all these kind of sprays any tips?

Thank you

Picture not loading help?

[Bruces]

I am from Sudbury and also have a home in Wasaga Beach l

[Diggy]

Hi Diggy, Bruces eluded to my XL185/CG250 swap project thread which you might find useful.

I am not sure how extensive the dents in the tank are or if you are trying to preserve original paint/patina but i just went cheap and used filler for small pea and peanut dings.

As for 6V LED... I don't believe there is as an extensive range of options. Most if not all modern stuff is 12V LED. But just try searching aliexpress or similar and with a bit of tinkering and DIY i think it could be done.

the RFVC engine is pretty bulletproof but I think your biggest issue might be trying to replace a 23" front tire if that is what it has equipped.



Why change the front tire?

[franque]

Uh, because it's old and needs a new one!?

[OldmanofMn]

I just picked up a 1971 CB 175 :)

[Diggy]

Test

[Darkrider]

I was once in the same position with an XL that i ended up selling. However the path i ended up looking towards was converting the bike to 12V with the parts available out there. Had planned on using a small SLA type battery in a custom airbox/battery box. Or just ditching the air box in favor of a pod to make space for a battery. However not knowing how the 250 is laid out frame wise i am not sure what to suggest.

[Diggy]

Anyone have any tips in buying an air filter for this bike. I took this one out and it’s pretty oily black dirty ripped.

Also the spark plug. What is the best thing to do? eBay? Or Honda? Prime?

Thanks

[Diggy]

Well I just found out that the bike has to be kicked started. I really thought there was a electric start. So all I really wanted to investigate is how to put LED lights in with a 6v system. Is it even worth doing? Any tips would be helpful!

Thanks

Also with the gas tank I’m going to strip it and to fix those dents I pretty much think of puttying or what they call it I can’t remember. Heheh
Sand etc and then prime and paint. What about heating it up hmmm and trying some how to push up. Hmmmm

[Bruces]

Without seeing what your tanks damage looks like ,it’s hard to help with the repairs ,different types of dents need different methods ,if they have creases it’s harder to straighten them than if they are just pushed in smooth . The plug and air filter would be available at the dealer although many aftermarket parts sellers would have access to them as well .

[cheesy]

https://www.ledlight.com/6-volt-negative-ground-automotive-led-lights.aspx

Should have everything you are looking for.

[OneLeggedRider]

Uhmm.. back in the 80s pretty much anything that was dirt oriented had to be kickstarted, even if it was a 500 or bigger.

[Diggy]

Ok lights!!!

The headlight that came on the bike was cracked and the bracket as well.
I did not know that the head light was one solid bulb! My friend came over and was looking at the bike and he has a 78 Honda I think 185 something like that. He took off his speedo and head light device on his bike and he was going to throw it out! He brought me it and said try it out! So when I looked at them both I noticed that the 78 year one was a little bit smaller. I’m still thinking of switching everything over to LED so I’m still thinking of a different way to do this for this bike. Hmmm

We priced out a new basic bulb for it and was about 80$ with shipping Canadian!