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HONDA XR 250 REBUILD [message #285938] Tue, 30 September 2014 22:49 Go to next message
w00dzy is currently offline  w00dzy   United Kingdom
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(4) WSS Racer
Hello everyone!! Been a while since I've been on here! Hope all is well and good?! Thumbs Up Grin

I am looking for some assistance on rebuilding the bottom end of my xr 250.. This bike has turned into a full rebuild and has set me back a small fortune but when it was running well it was a joy to ride.

Its had the forks refurbished, new bearings everywhere, new pads, new mastercylinder, 2 different bottom ends (now repairing one) the other had an odd issue with the balancer shaft and was very knocky..

Check out these threads..

http://www.xrv.org.uk/forums/xr/96018-my-first-trail-bike-xr 250r-1997-a.html] http://www.xrv.org.uk/forums/xr/96018-my-first-trail-bike-xr 250r-1997-a.html[/url]
http://www.thumpertalk.com/topic/1056607-my-first-dirt-bike- xr250-1997/

Currently I am at this stage of the bottom end build:

crank bearings off..

http://i303.photobucket.com/albums/nn151/w00dzy1/Honda%20XR250R%201997/20140918_213842_zps5djrzknp.jpg

2nd snap on tool purchase Grin

http://i303.photobucket.com/albums/nn151/w00dzy1/Honda%20XR250R%201997/20140918_215745_zpspmwkvbbv.jpg

So I have installed the new bearings in the crank cases using the oven/freeze method which worked a treat despite some odd looks from my fiance! I decided to use bearing retainer where it appears the bearings have moved at some point previously whilst in the cases.

Oven clean on my job list hah

http://i303.photobucket.com/albums/nn151/w00dzy1/Honda%20XR250R%201997/20140930_183424_zpswgmelzlk.jpg

I have just started reinstalling the gearbox.. I put the cases back together without the crank in as a test and found that it doesnt seem to shift into all the gears? How do I ensure that its been correctly installed? I followed my tear down photos as guidance as the haynes book of lies does not detail this.

http://i303.photobucket.com/albums/nn151/w00dzy1/Honda%20XR250R%201997/20140930_204841_zpsob1gyfkh.jpg

http://i303.photobucket.com/albums/nn151/w00dzy1/Honda%20XR250R%201997/20140930_204844_zpstkw91bnv.jpg

http://i303.photobucket.com/albums/nn151/w00dzy1/Honda%20XR250R%201997/20140930_212920_zpsolmmv8dw.jpg

Also when installing the crank, is the rhs bearing a slip fit as this seems to be the case??

I am going to press on the lhs initially but need to borrow a crank puller off someone as they cost a fortune new considering the use it will get.. going to look into making one I think..

Tusk Crank Puller Installer AND Crankcase Separator Splitter Tool Motorcycle ATV | eBay

[Updated on: Tue, 30 September 2014 22:52]

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Re: HONDA XR 250 REBUILD [message #285975 is a reply to message #285938] Wed, 01 October 2014 21:40 Go to previous messageGo to next message
gone2 is currently offline  gone2   Netherlands
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(15) Kenny Roberts
regarding the gearchange, I would suggest putting it into first gear by moving the dogs and then you know that at least one of the forks has to sit in the end of a groove in the selector drum (because in first you can't go any further). dunno precisely how to do it but that's what has to happen.
regarding main bearing, a slip fit with the crank is ok, provided it's not too loose a slip fit (is the crank journal worn?). Oil will get in there and stop any possible rattling.
Re: HONDA XR 250 REBUILD [message #285980 is a reply to message #285938] Wed, 01 October 2014 23:27 Go to previous messageGo to next message
w00dzy is currently offline  w00dzy   United Kingdom
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Thanks for the reply.. Thumbs Up

A mate fabricated a puller for me today and I've now got the cases back together and gears working fine. I now have a fully refreshed bottom end.

Now I have just removed the valves to inspect for potential oil seepage issues and found the they valves wobble a little in the guides... got a feeling they will require replacement. I will look into measuring them first. Are they meant to have zero side to side play? The manual states to measure top, bottom and middle point to see if it's out of spec but I don't have the correct tool to measure them currently.
Re: HONDA XR 250 REBUILD [message #285981 is a reply to message #285980] Wed, 01 October 2014 23:30 Go to previous messageGo to next message
w00dzy is currently offline  w00dzy   United Kingdom
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http://i303.photobucket.com/albums/nn151/w00dzy1/Honda%20XR250R%201997/20141001_213255_zpsf3er4vaz.jpg
Re: HONDA XR 250 REBUILD [message #285982 is a reply to message #285981] Wed, 01 October 2014 23:31 Go to previous messageGo to next message
w00dzy is currently offline  w00dzy   United Kingdom
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Amazing how simple the bottom end is! (now I've got my head around it)!
Re: HONDA XR 250 REBUILD [message #285988 is a reply to message #285980] Thu, 02 October 2014 11:49 Go to previous messageGo to next message
gone2 is currently offline  gone2   Netherlands
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(15) Kenny Roberts
The question is, have the valves worn or is the the valve guides, or both? A simple micrometer check on the valve stem below where it make contact with the guide and then compare with the diameter further up should give you the answer.
I suppose if it's not burning oil then there's nothing urgent required, but for good order you might have to consider replacing both valves and guides. No biggy. Unless of course you also want to recut the valve seats - and then you might want to get it done by a machine shop.
Re: HONDA XR 250 REBUILD [message #286004 is a reply to message #285988] Thu, 02 October 2014 22:18 Go to previous messageGo to next message
pecker is currently offline  pecker   United Kingdom
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(11) MotoGP Podium Finisher
looks a good job your doing there woodzy Thumbs Up

when i stripped my boys bike down it was not as scary as i thought it might be

and a Black and Decker Workmate in shot Thumbs Up

PS. why is our job to clean the oven after they have cremated everything they put in it Laugh
Re: HONDA XR 250 REBUILD [message #286018 is a reply to message #286004] Fri, 03 October 2014 22:29 Go to previous messageGo to next message
w00dzy is currently offline  w00dzy   United Kingdom
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Cheers lads! Its taken some time and been a real learning experience thats for sure.. looking forward to riding it again as we have plenty of green lanes where I live..

Turns out its the guides and valves. Ive also read that the intake valves are notoriously soft.. I sourced a brand new head earlier in the year for a good price (with guides installed) which I'm going to use..

Ive just ordered a valve spring kit and planning on sourcing the valves at a reasonable price..

http://i303.photobucket.com/albums/nn151/w00dzy1/Honda%20XR250R%201997/Screenshot_2014-10-03-22-12-48_zpszgkdetr6.png[/URL][/img]

P.S I tend to do the cremating and cleaning? Somethings wrong here lol.. Although her small feet come in handy at getting close to the sink to do the washing up hah
Re: HONDA XR 250 REBUILD [message #286019 is a reply to message #286018] Fri, 03 October 2014 23:39 Go to previous messageGo to next message
Kermit is currently offline  Kermit   United Kingdom
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(22) Giacomo Agostini
Looking good woodzy, I take it your concentrating on the mechanicals first then moving onto paint and cleaning or are you just getting it working well and sod the look given its destination?

[Updated on: Fri, 03 October 2014 23:39]

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Re: HONDA XR 250 REBUILD [message #286020 is a reply to message #286019] Sat, 04 October 2014 11:00 Go to previous messageGo to next message
Quazi is currently offline  Quazi   United Kingdom
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(22) Giacomo Agostini
Good on ya Woodzy.


If it were me, I'd be sticking bronze valve guides in there and run them without stem seals. My XT500 has bronze guides as the XT was notoriuos for burning the exhaust valve dry and knackering the cam as a consequence. It will of course burn small amounts of oil, but we're not talking clouds of smoke out the back, just evidence of soot in the exhaust.

Japanese guides are too hard but last for years which is why they use them, bronze guides are far superior to the standard option, you just won't get 100,000 miles out of them.

Judging by your original cam I'd say it has been low on oil also at some point during its life.

Thumbs Up


Re: HONDA XR 250 REBUILD [message #286025 is a reply to message #286019] Sat, 04 October 2014 23:29 Go to previous messageGo to next message
w00dzy is currently offline  w00dzy   United Kingdom
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Kermit wrote on Fri, 03 October 2014 23:39
Looking good woodzy, I take it your concentrating on the mechanicals first then moving onto paint and cleaning or are you just getting it working well and sod the look given its destination?



Cheers Kermit, hope all is well?

Been looking at your xr, you did a nice job with it..

Yeah mechanicals first and I'm thinking should I paint it all up considering its going to scratch off in a few months? I would like the engine to be black and I bought the paint to do it, but have gone off the idea as it just didnt seem practical.

Re: HONDA XR 250 REBUILD [message #286026 is a reply to message #286020] Sat, 04 October 2014 23:47 Go to previous messageGo to next message
w00dzy is currently offline  w00dzy   United Kingdom
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Quazi wrote on Sat, 04 October 2014 11:00
Good on ya Woodzy.


If it were me, I'd be sticking bronze valve guides in there and run them without stem seals. My XT500 has bronze guides as the XT was notoriuos for burning the exhaust valve dry and knackering the cam as a consequence. It will of course burn small amounts of oil, but we're not talking clouds of smoke out the back, just evidence of soot in the exhaust.

Japanese guides are too hard but last for years which is why they use them, bronze guides are far superior to the standard option, you just won't get 100,000 miles out of them.

Judging by your original cam I'd say it has been low on oil also at some point during its life.

Thumbs Up




Nice to see familar faces on here! Thumbs Up
Glad the forums still lively..

Bronze valve guides look appealing considering the can be sourced from kibblewhite.. I have just ordered kibblewhite valves to go with the springs but was hoping that the brand new honda head and guides should be fine?

Yup the original engine that came with this bike had nipped up at the top (low on oil) guys kid had used it as a farm bike and said it just needed a top end build. I have ended up replacing everything on the bike!! Laugh I am using the bottom end that came with the bike (now refurbished), new head, new piston, cam and rockers from another spare engine which was shagged..

I have however learnt a lot from it and also managed to have some great rides so far..

My first ever off road ride



First of many, many crashes



Night laning by candle light, rambler in the middle of nowhere lol!!



More night laning



First slippery hill climb






Re: HONDA XR 250 REBUILD [message #286028 is a reply to message #286026] Sun, 05 October 2014 11:37 Go to previous messageGo to next message
w00dzy is currently offline  w00dzy   United Kingdom
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Decided to stick with original guides as I have it on good word ( from a guy who owns a fleet of these bikes) that the oem valves are fit for purpose with the kibblewhite valves
Re: HONDA XR 250 REBUILD [message #286029 is a reply to message #286028] Sun, 05 October 2014 20:41 Go to previous messageGo to next message
Kermit is currently offline  Kermit   United Kingdom
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(22) Giacomo Agostini
Good vids as hadn't realised you'd managed to use it yet, pretty much the perfect sort of engine in terms of power and torque for green lanes Thumbs Up

What bike has the guy in the orange got as he fell so going to assume its a lesser model Laugh

Re: HONDA XR 250 REBUILD [message #286062 is a reply to message #286029] Tue, 07 October 2014 19:24 Go to previous messageGo to next message
w00dzy is currently offline  w00dzy   United Kingdom
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Cheers, it is a great bike.. Yeah its a bit miss leading and I've got a few threads running in different forums (to help me gain as much knowledge as possible)

Heres one of the original ones which shows what it was like when I first got the bike..

http://www.xrv.org.uk/forums/xr/96018-my-first-trail-bike-xr 250r-1997-a.html

Full restore project! The previous owner advised everything was good apart from the top end, paid £400 off ebay for it and had it delivered.. not one thing that didnt need doing..

I managed to get it running well for some time by using parts from other engines etc #bitsabike.

Yeah the orange ones always seem to be crashing Wink But the guy in the orange jacket is me on this bike lol!!
Re: HONDA XR 250 REBUILD [message #286063 is a reply to message #286062] Tue, 07 October 2014 19:28 Go to previous messageGo to next message
w00dzy is currently offline  w00dzy   United Kingdom
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Really looking forward to getting out on it again Grin

Do you still have an off road bike?

Re: HONDA XR 250 REBUILD [message #286064 is a reply to message #286063] Tue, 07 October 2014 19:29 Go to previous messageGo to next message
w00dzy is currently offline  w00dzy   United Kingdom
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The venom karts look a right laugh!



Serious bits of kit not to be sniffed at!!
Re: HONDA XR 250 REBUILD [message #286067 is a reply to message #286064] Tue, 07 October 2014 20:10 Go to previous messageGo to next message
Kermit is currently offline  Kermit   United Kingdom
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(22) Giacomo Agostini
They are, only been out once so far at a shorter twistier track than in that video but its good fun Grin (once I got the damn thing started* Wall )

*Carb issue hopefully now resolved

[Updated on: Tue, 07 October 2014 20:11]

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Re: HONDA XR 250 REBUILD [message #286168 is a reply to message #286067] Fri, 17 October 2014 23:33 Go to previous messageGo to next message
w00dzy is currently offline  w00dzy   United Kingdom
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So my parts have turned up..

I have fitted the valves tonight to test fit.. they look to have great seating with no lapping. Not suprised considering they are brand new along with the head..

I have measured the spring length as per the instructions and they seem ok at just over 1.2. I thought these valves would be easier to fit.. anyone have any guidance? I would ideally like to do all the work myself and have the satisfaction..

Pics to follow 
Re: HONDA XR 250 REBUILD [message #286169 is a reply to message #286168] Fri, 17 October 2014 23:37 Go to previous messageGo to previous message
w00dzy is currently offline  w00dzy   United Kingdom
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