Bikervation - 1996 Honda XR250R Restoration Project

Honda XR250RT restoration photographs of the project: goo.gl/photos/3H3iymqutJzsstCf6
A short video of the 8 Month restoration of my Honda XR250R, from June 2015 to February 2016. I couldn't load the still pictures into the video very well (that's why the voice-over is dodgy)so here's a link to the Google pictures XR250 album: goo.gl/photos/3H3iymqutJzsstCf6

[@1982JOEC]

That's one of my all time favorite bikes!!..Love the video and great work my friend!!

[@Bikervation]

Thank you.

[@lukeinkson]

Nice work! I can relate to the startup procedure hahaha "choke is on....*kick*... half choke now *kick*.....okay choke is off... *kick kick*...hmm....choke is back on... *kick*" 🤣 gotta love XRs

[@Bikervation]

Hi, Thanks for watching, I eventually got the bike to start first kick! The throttle cable was incorrectly routed around the throttle butterfly!

[@user-jj6dh7zg7x]

Just bought a 87 today! Absolutely love it. Will be following your page to get some tips on maintenance. First thing to check tomorrow is the swing arm pivot bolt. Thanks for the video. Going to have a look on your page now, hoping to see this bike in action!

[@Bikervation]

Hope it helped, ride safe. :)

[@UlisesGlez26]

I have my 2001 since 3 years now, and I'm never going to leave her, those bikes are indestructible

[@Bikervation]

Agreed :)

[@r_s_enduro]

I just bought a one owner garage kept 2000 barely touched. One kick every time no bog hella perfect condition and i waited for a loooooonnnng time to come across this bike. Very happy i was patient

[@jakobwhiddon6033]

I guess you can call me an unstoppable force cos I broke the indestructible object big time

[@UlisesGlez26]

@@jakobwhiddon6033 what did you do? 😄

[@jakobwhiddon6033]

Let’s just say a lot of burnouts

[@crazeyspivey]

My 90 XR250R is also a bit cold natured on start up......I just let her purr on full choke for 15 seconds, then run on half choke for a few minutes, and then she is ready to Getty-Up. Love the power and suspension.......unstoppable.

[@whitecompany18]

Good honest video mate .

[@johncarlson1877]

It looks Excellent how it is and it's soooooo food to see you riding it. Us older guys don't have to go warpspeed anymore but going slower is ok by me keep on riding and never sell tour XR 250 R because you will regret it forever! Peace. I subscribed qe'll talk again...John

[@johncarlson1877]

Nice job

[@walterconn5637]

Thank you for the video! It looks very similar to my 96 XR250R. I enjoyed watching your XR come back to life. I would be interested to follow any updates on your XR. The previous owner of my bike rebuilt the top end of the engine. Hopefully these bikes will last a while longer.

[@Bikervation]

Hi, Thanks for watching and your comments. Unfortunately I sold the XR, it kept throwing me off for no good reason! See my greenlining Ridge Way video where I have a couple of spills. I thought it’s only a matter of time before something gets broken a few miles from anywhere, so decided to stick to the Harley which I find great fun and grin inducing. One thing I would say is keep an eye on the rear swingarm through bolt, they get stuck and unmovable which means you can’t get the engine out should you want to. Ride safe, Chris

[@walterconn5637]

Ruts are the worst. They look harmless to the untrained eye. Your video has helped me to be on the lookout for them. I was going to say "At least you are not stuck in a rut anymore," but that would be a bad joke.

[@Bikervation]

@@walterconn5637 Agree about the ruts, that and little rocks, I could not keep my arms lose enough, I knew I had to let the bike steer but could not looses up. :)

[@mattie_world]

looking at buying a 98 for 1500, absolutely beautiful bike, cant wait!!!!!

[@mattie_world]

ps u have some cracking vids BV! subbed!

[@Bikervation]

Take care, the swing arm pivot bolt is pron to seize if not maintained, which can lead to a World of grief.

[@chrisredfield3240]

+BikerVation had to cut mine in 3 pieces all fixed now new bolt and lots of grease and will pull it out now and again

[@springy-2112]

hey great video i've not had an xr but had a 76 xl250 (the one in my logo ) wish i still had it just as something opposite to my normal modern ish stuff..👍☮❤

[@Bikervation]

Hi, Thanks for your comment, I loved the bike and it was rewarding restoring it, I only wish I’d had a camera to record the restoration as that would have been a great video. I’ve sold it now as it kept throwing me off (see the greenlining video) and I thought something is going to get broken. Still enjoying the Harley though, Ride safe

[@mkaushalmd]

HI, I looked through your videos, pretty cool. Do you have one that shows how to remove and clean the carburetor on the Honda 96 250XRL or can you recommend a video, The local shop wants as much as the bikes worth to remove, clean and put it back on!!

[@Bikervation]

Hi, thanks for your kind words, unfortunately I don’t have any videos on stripping the carb and don’t know of any on KZbin offhand. I expect you will find a few on stripping carbs with a bit of searching. Good luck, Chris

[@gonzalomiranda9570]

Awesome job on the restoration!!! I got exactly the same bike and I was wonder if you remember from where did you get those mirrors. I need to install that and also the turn lights. Regards from Argentina.

[@Bikervation]

Hi, Thanks for your kind comments, this was a few years ago now and cant remember who makes the mirrors, they are folding ones and I probably bought them on EBay. Hope that helps, ride safe, Chris

[@felipesuarezweb]

Hi guys, I am getting one of these bikes in a couple of days. Thanks for the video. I think this bike is very cool and powerful.

[@MINIMOTOMADNESS]

i have a 1996 same colour with electric start,what a machine

[@Bikervation]

Agreed :)

[@peytonmcadams7562]

I must ask, whyd you start the bike from the side, as opposed to starting it from the riding position? Great job on the restoration! always good to see old bikes get a new lease on life.

[@Bikervation]

It’s how I’ve always kick started bikes, personnel choice I guess. :)

[@timduthie6399]

I had a 1996 XR250R and I think that thoughts stickers are the wong ones, I think they are for a 1998. And the folk boots should be blue the same as the head light.

[@adambagwell40]

I have a '99 xr 250r. Never had to do anything other than change the oil, and clean the air filter. Problem free bike. Add gas, give it a kick, and you are good to go. I have more issues with my $3500 mountain bike, than my XR.

[@loll1974]

Lovely bike im restoring one now .Were did you get the bash plate from.Cheers.

[@Bikervation]

Hi, thanks for your comment, and agree an awesome bike. I’ve sold it now because it kept throwing me off. The Skid plate was an Acerbis #9522 very sturdy, hard plastic that could take a beating. After a lot of research I thought it the best. Hope that helps, ride safe, Chris

[@loll1974]

@@Bikervation thank you

[@ryanhamel1071]

Did you hook the indicators up to the headlight wiring or directly from the stator?

[@Bikervation]

I came off the regulator/rectifier because the LED flasher needed DC.

[@MINIMOTOMADNESS]

might seem a strange question,but i have an intermittent tapping sound coming from my engine, its a 96 250 by the way,do they have cam tensioner problems?

[@Bikervation]

Hi, sorry I have no idea, mine was quite a noisy engine though.

[@iMrPereira]

Please do post some more videos maintenance related. Cheers from a new subscriber

[@Bikervation]

Thanks for subscribing, I intend to post videos of everything I do to the Honda, riding and servicing, at the moment I'm trying to get my audio on the Bandit camera sorted so it may be a while before I can get back to it.

[@haydenfrench7878]

Nice bike runs well but seems like the valves are very rattly. Are they adjusted to the right specs? Intake .004" exhaust .005"

[@Bikervation]

The spec is correct for my bike/model/year, I will be doing a video on valve adjustment - but not until later in the year, I find mine is a bit rattly. When adjusting, first make sure the engine is cold and the decompression cable is released (slack) then turn the crank shaft 3 full revolutions before finding the timing marks, then check the clearance - particularly on front right exhaust valve.

[@haydenfrench7878]

+BikerVation I know how to adjust the valves. Mine is nice and quiet. Are you sure when you adjusted yours it was on the top of compression stroke and not exhaust stroke? Like I said mine are very quiet you can watch my video if you would like to see how they should sound.

[@Bikervation]

Sorry, I miss read your first comment, yes I check the valve clearance on the compression stroke (all valves closed), could be the timing chain needs looking at. Also I think it’s had a hard life, we all get a bit rattly later on.

[@mitropoulosilias]

what headlight you use? Can you drive at night on full dark with that headlight?? also, do you have any website that you can buy parts?

[@Bikervation]

Hi, I sold the XR a few years ago, from what I remember the head light was the standard 60/55w and wasn’t that bright at night. I don’t deal in parts and most of the parts for the rebuild came from EBay. Thanks for watching. Chris

[@gonzalomiranda9570]

You can put some really bright LED by changing the current to continuous. Just get a 25v or 35v diode bridge and a 4700uf 25v condensator and you will good to go. If you need specifics let me know.

[@Bikervation]

@@gonzalomiranda9570 Thanks for your comments and the info, unfortunately the bike was sold, stay safe, Chris

[@gonzalomiranda9570]

@@Bikervation ok. Good luck!

[@Gamebit450]

Looked at the time of the video half an hour sweet get to watch the whole bike build. 3 minutes into it fast forward all the way to the end and it was just decal placement LOL

[@Bikervation]

Thanks for watching what you did, I do mentioned I unfortunately had no video camera when I was restoring the bike so linked some of the stills goo.gl/photos/3H3iymqutJzsstCf6 It took over 8 months and cost close to £1900 before it was finished.

[@matthewgodfrey9025]

how have you wired up the indicators, looking to do the same with mine, do you need to install a battery or can you just connect onto the existing system ?

[@Bikervation]

Hi, You don’t need a battery but the indicators would only work when the engine was running. I used an LED flasher unit and LED indicators, I took the feed from the regulated 12v supply. Hope that is of help, Chris

[@matthewgodfrey9025]

@@Bikervation do you need 2 separate blinker units to run each side or do you put the blinker inbetween the regulator and the indicator button ?

[@Bikervation]

@@matthewgodfrey9025 You only need 1 blinker unit and 2 diodes in a little circuit, if you email me I'll send a pic to you, I cant seem to post it here! Chris

[@matthewgodfrey9025]

@@Bikervation what's your email address , can't seem to find it ?

[@Bikervation]

@@matthewgodfrey9025 [e-mail]

[@johncarlson1877]

He was a bodger cuz I had all original decals after 12 years of riding and racing, and still the original clutch. I'd love to save the older bikes and wish we worked together young fella...mine was a 94 xr250r

[@kylebroflofsky6147]

did you intend to do a restoration or did you buy the bike thinking it would only need a few things. seems like you put much more then the bike was worth into it.... my step dad is restoring a Honda CR60... its 2-stroke and i rode it just before he disassembled it and the thing was scary fast for a bike that small. im 6.2 tall at 165 pounds and the thing would wheelie with me on it all day kickin roosts and swingin the back end out. the guy sold it because he wouldnt let his 5 year old daughter kill herself on it.

[@Bikervation]

I never intended to spend £1900 on a bike that I could probably only sell for £1500 at best. But I did want a project and I love working on bikes. The project and the joy I get from it was always the main purpose and of course to end up with a Dirt Bike to ride Green Lanes. When I was working on it I was aware of the point of no return and decided that making a profit was not the goal so plodded on happy. Also I have learnt so much about these bikes which I would not have known unless I rebuilt it. I would not have known what to look for if buying from scratch and could have got a lemon costing just as much.

[@nonormies2837]

Just got my 96

[@MagicusBolivia]

where can i buy those tank decals?

[@Bikervation]

They were £40 from an e-bay shop: dirtbikedecals stores.ebay.co.uk/dirtbikedecals/ They are quit thick and mine have rippled after a couple of Months ( still look OK ), so I don't know if thinner ones would be better, although they would probably scratch!!

[@emigrant4life]

where is Restoration ? Only a stikers...

[@thecars570]

Nice ride. I’m restoring a 96 as well. Your using 97 graphics, though.

[@Bikervation]

Hope you have better luck with the swing arm bolt :)

[@thecars570]

BikerVation I was lucky......My swing arm bolt came right out. How are your gas tank graphics holding up over the years? Any pealing?

[@Bikervation]

@@thecars570 The graphics didn’t hold up so well but they were cheaper than the original ones. I’ve sold the bike a while ago as it kept throwing me off. A good idea to service the swing arm bolt is take the weight of the back wheel and drive the bolt out with a ½” plastic bar (the sort you can turn on a lath) that’s long enough to replace the bolt so you can grease it up. Then drive the bar out with the bolt. Saves taking the back end apart. Ride safe, Chris

[@stublackshaw7561]

If you use soapy water to position your sticker, you can move it around until you are happy with the position. I have just finished restoring a 1988 XR250, and this is the method that I used. To replace the vinyl stickers on the early sidecovers, I used soapy water and a heatgun, to soften the vinyl too conform to the curved surface.Here is a before and after pic.advrider.com/index.php?threads/the-xr250r-thread.430219/page-155#post-30267384

[@Bikervation]

Nice bike :) I think that’s correct for the transfer type that you “float” on, but these had a very sticky back and would not have worked had I used water, thanks for the input, ride safe.

[@johncarlson1877]

Why don't you google a pic of the 96 xr250r before you place decals?

[@Bikervation]

Hi, the proper decals were too expensive for my liking but I did look.

[@Bikervation]

Hi, the proper decals were too expensive for my liking but I did look.

[@Bikervation]

Hi, the proper decals were too expensive for my liking but I did look.

[@sigma7568]

clac,clac,clac...

[@heinrichvonkekelnazi393]

Woah, XR's have always been engines that make ticking, clanking sounds, but your bike sounds like something wrong with it. Would check to make sure a rocker didn't pop off, or poorly adjusted. That's definitely a valve train issue

[@MINIMOTOMADNESS]

mine sounds the same,

[@lemonprofit5147]

that didn't sound right though. to much ticking maybe head ?

[@Bikervation]

you could be correct, it does quieten down some what when warm, so probably some expansion going on, also it's getting old and we all get a bit rattly with the advancing years.

[@zimos5842]

i just got a 97!

[@Bikervation]

Nice one, I’ll be doing some basic maintenance videos this year, things like changing the oil and servicing the brakes that could be of interest to you.

[@zimos5842]

BikerVation Sure is you earned a sub!

[@chrisredfield3240]

I have a 1996 imported in 2000 the electric start one, I had a uk 1998 brand new.

[@moon-jc4pq]

wtf with sound of valve...?? tik tik tik

[@nonormies2837]

Just got my 96

[@Bikervation]

Enjoy :)