How to Modernize a Vintage Motorcycle | The Shop Manual

Enter Cycle Gear’s 50th Anniversary Sweepstakes for a chance to win a custom 1974 Honda XL250 and a 2024 Honda Transalp! rvz.la/3QOvfyk
Turning a vintage motorcycle into a dependable daily rider can be a challenge, but there are a handful of key mods and upgrades that will help modernize your ride and make it a lot more reliable. In this episode of The Shop Manual, Ari gives us an overview of the steps he took to restore a 1974 Honda XL250 and turn it into a one-of-a-kind custom.
RevZilla has all the parts and upgrades you need for your own restomod. Here are some of the products Ari did to build this one-of-a-kind bike.
Electronics:
Motogadget mo.unit blue power distribution device rvz.la/3VcoRDL
Motogadget Chronoclassic speedometer rvz.la/3K2mFs5
Motogadget mo.blaze pin LED turn signals rvz.la/3UObbxn
Motogadget wiring kit rvz.la/3wIuY9m
Duraboost AGM 12V batteries rvz.la/3wD98Ee
Denali Mini Soundbomb 113 dB horn rvz.la/3V9a24A
Suspension, brakes, and tires:
Shinko SR241 “Golden Boy” tires (the unofficial official tire of CTXP vintage adventures) rvz.la/3wEFPRy
Race Tech Gold Valve Emulators rvz.la/4eRIFnM
Progressive 490 Series adjustable shocks rvz.la/3UOE502
Spiegler braided stainless steel brake lines rvz.la/3V3Lb24
Nuetech Tubliss Gen 2 tubeless tire system rvz.la/3yjdsZA
Controls:
Motion Pro CR Pro SE throttle assembly rvz.la/4dPgXaw
Motion Pro Dirt Control II grips rvz.la/4dJ6jSN
Motion Pro throttle cable rvz.la/3UKn1IK
Motion Pro clutch cable rvz.la/3WIXVMU
Motion Pro fuel line rvz.la/4apdlZR
Miscellaneous and useful stuff:
Bolt Hardware metric bolt kit rvz.la/4bNpXuZ
Moose Racing universal ignition switch rvz.la/4boreJ2
Thanks to Progressive for sponsoring this episode of The Shop Manual. Learn more about America’s #1 motorcycle insurer at bit.ly/4bxgurZ

[@RevZilla]

Win this bike by entering Cycle Gear’s 50th Anniversary Sweepstakes! rvz.la/3V3MhLe

[@Misterrocckettaro]

Why does it say that is ended the 7th of April?

[@Tom-nx6ev]

@@Misterrocckettaro It's in month/day/year format.

[@Misterrocckettaro]

@@Tom-nx6evDamn! Always forget that; thank you!

[@MarkLoweLowebrau]

No Canadians allowed?

[@Xaiux]

@@MarkLoweLowebrau seems so :(

[@JB-tj9mm]

Sounds like this 250 needs to be on the Daily Rider before it’s give away. Wish we could have seen and heard it run. Amazing rebuild!

[@AriH211]

Zack had the XL on the DR route last week, so you'll be seeing it in action soon!

[@Tom-nx6ev]

@@AriH211 Woohoo!

[@niklas4042]

The bike looks damn good, but please let zach or ari for a change up do a daily rider episode of it before it goes. Great video.

[@Tom-nx6ev]

Completely agree with the Daily Rider suggestion.

[@Wintersdark]

We need a daily rider on this bike! It's beautiful, Ari. Amazing work there. Beautiful.

[@mcnuggetapple]

We got it now!!

[@TheRogueBro]

"...that's clearly way more than we can detail in one episode..." So two episode series? I always loved Ari's builds!

[@uberade386]

Yeah give us the rest of the content here, I'd gladly watch hours of this resto

[@DankoStojanovic]

Did I miss a rebuild series? Anyway, a daily rider on this little gem is a must. Please let Zack give it a spin

[@battleax002]

I would enjoy a much more in depth video on the build. I get a kick out of your amazing videos, but a video more detail would be fabulous….. I’m heading down to the shop to continue work on my ‘66 T120TT…….

[@9roads]

100% agree

[@Mack7830]

man I would watch Ari wrench on bikes all day if they'd let him record it, top notch stuff

[@22corgis]

I'd love to see this bike being ridden Ari did an amazing job of modernizing this bike. Consider putting this on an episode of Daily Rider please (and thank you!)

[@AriH211]

Stay tuned!

[@Kingsoupturbo]

So much work! lengthened swing arm as well! the guy who built it, should be keeping this one, a labor of love!

[@DBAUG]

Want to see this XL running!

[@John_Ridley]

Wow that power module is VERY cool.

[@SaffronWorldCR]

Would love to see this converted into a series of videos.

[@trevor8419]

I bought a Yamaha SR 400 for its vintage charm without the vintage maintenance. Your xl looks great!

[@nseric1233]

I have a SCR950 for similar reasons, it looks old but is a dead reliable low maintenance modern cruiser.

[@trevor8419]

@@nseric1233 I considered the SCR. I think it's an awesome looking bike, I heard it's kind of uncomfortable, like the airbox sticks into your leg. How is it for you comfort wise?

[@nseric1233]

@@trevor8419 Sit on one before buying it. Im short and the airbox doesnt bother my leg. The seat is pretty hard, im uncomfortable after an hour on it but that's all the long 9/10 of my rides are so I like the bike just fine.

[@888johnmac]

WHAT !! only 8 mins long .. i feel robbed .. lol

[@pmdinaz]

Holy bananas Ari! What a fantastic result. As someone who has only done simple modifications to my own bikes, I can truly appreciate the amount of work and determination you put into this one.

[@FT__Motorcycles_Cars____-zg3fc]

at the risk of sounding weird - that damage you had to your face/jaw/mouth (whatever it is that was messed up) has been healed/fixed so much it is surprising. That's impressive

[@TheClarkenstein]

Damn - had no idea stuff like this existed. My last CB350 project would have been a lot different.

[@brucelange730]

Ahhh -- I now remember why I will never buy a vintage bike. I used to think I was a hot shit rider, then I saw Joey Dunlop ride. Ari does the same thing for workshop stuff. I max out at clutch replacement.

[@shawnphillips4473]

That power distribution block is awesome I may need that for the old triumph I just picked up Love the videos keep them coming

[@ChesterThomasHupp]

Great job, love the vintage XL! I own a '94 XR250L but my heart remains connected to the 70's dual sports....I grew up on them1

[@UnliRide]

Man, it's beautiful. Hope it gets a Daily Rider EP before it goes.

[@ricatiman]

OMG! Back in '72 when this bike came out, I was racing flat track, and the dealership I was at converted one of these into a TT bike! It had been dropped on a test ride, so was an ideal starting point. With little more than a few hours of stripping down, it was track ready. Not a fast bike, but totally fun to ride! It made an excellent pit bike for the team. I continued to race my on Bultaco Astro ...

[@bensonG92]

Love it! Excellent work in creating this masterpiece from an Old Honda Ari. The choices that you took to customize the bike into this new look is something that only an experienced motorcycle lover can pull off. Kudos to the winner of this bike! Hope it’s me lol 🤞🏽

[@5tr41ghtGuy]

This is an inspiring yet practical restomod of a vintage bike. For folks who like to tinker with bikes, the upgrades you outlined look like very worthwhile - thanks for creating and sharing this video!

[@seniorsouthwick976]

Had to enter this raffle. The 1974 Honda XL250 was my first bike and my daily commute to high school and work. Also saw quite a bit of off roading inclusive of an airport runway crossing landing me and a friend, on a 1975 XL350, in the can for a Sunday afternoon. That bike never left me stranded, although it was somewhat heavy and lacked the light weight and quickness of the 2 strokes that became more popular. I eventually sold it and picked up a 1975 Yamaha DT400 2-stroke, oil-injected, which was another dependable on-off bike that created its own unique legacy. After 40+ years of riding Harleys, I’ve come back to Honda and street ride a 2021 GoldWing DCT Tour.

[@KingTroopa]

Transalp and an Ari restored XL250, What a dream 🤩 How do we get the extended cut ASMR video of the restoration?

[@thewatcher5271]

How Cool Is That!?! I Remember Reading About It 50 Years Ago. Doug Schwerma Made A Custom Frame & It Was Featured In A Magazine. Thank You.

[@acnohaki]

The tachometer was cool though. Should have included that also 😐. Would have completed the aesthetics.

[@Redmenace96]

Yeah. The dual clocks is part of the look. The replacement is much smaller and I couldn't see a dang thing on it when riding.

[@aumkar2]

Ari probably wouldn’t do that to his bike. I think this episode was stupid, an original bike destroyed.

[@dinkydotzero]

Gotta say, i love everything with Ari in it

[@jktho]

I entered the sweepstakes, Ari.

[@AriH211]

Good luck!

[@peterholthoffman]

This is what my friends and I are waiting for to find new in the showroom today! I had a 1972 XL-250 in 1976 and it was an absolutely fantastic motorcycle. I took it far, far off-road and never found a place I couldn't go. I also toured on it, going on a week-long camping trip which covered almost a thousand miles. It and my 1977 KZ-1000 LTD are the two motorcycles I most regret selling. I like how this bike was updated and modernized without destroying the profile or the spirit. It's absolutely beautiful and I'm certain it's a big improvement on the original which was incredible to begin with. I hope the replaced parts weren't tossed - someone restoring (which means "return to original condition") an XL-250 would find them valuable. Anyway, Honda - are you paying attention? Take my money!!! I would like to see a Daily Rider video about this bike as I can't help but believe it will come back as being darned near The Unicorn.

[@CustomerService-ut9tj]

Well done Ari. This is one of the best motorcycle videos I’ve ever seen in my entire life, very inspiring, very educational, and a good watch.

[@CommieHunter7]

I had a 1981 CB750. Rebuilt the brakes calipers, MC, full suspension rebuild, and got it running great. In the end, it was still heavy, with only mediocre braking. I realized that I'd be better off with a newer bike for the same money.

[@zemquoi]

Nice work! Beautiful! I would love to see a detail on that entire build.

[@davidcarr5718]

What an accomplishment. My XL was stolen when I was overseas. I would rather win the 250 over the Transalp. Nostalgia from my younger days. Excellent content. Thanks.

[@rgh622]

Yes, please send me the bike. Thank you

[@BoneyMB]

Brilliant work. Even visually one can see and feel(!) this great vintage look and modern technic fusion. Great, great, no other words!!!

[@momchilyordanov8190]

The final result is impressive. Well done.

[@AriH211]

Thanks! Glad you like it.

[@jakobkonradsen1248]

You should make more detailed longer videos of for example on how you changed the ignition system or that electrical box. It would be fun to get some more variety on the videos. Just film whatever you are working on, doesnt have to follow the same format you have done for years. Same goes for daily rider. Would be fun with some more variety.

[@Stromtoorper]

Can't get over how ripped this man is. Absolute unit.

[@piersmarchington]

Great to see you back

[@stephencooper5040]

I’m certain I speak for more than just myself when I say we want to see ALL of the nerdy details of completely transforming this bike to modernize it

[@Reinhardt1775]

Gotta love vintage bikes, i just got done getting my 1978 sohc honda cb750 SS back on the road after 13 years.

[@athiftsabit1208]

Damn, old dirtbikes silhouette are just beautiful

[@LTVoyager]

Add my vote for a series on the rebuild/modernization effort. Assuming it was videoed.

[@Telesko]

This came out at the perfect time! I was just given a 1974 Yamaha RD250 that I want to fix up.

[@monocogenit1]

That thing is sweet! I love old Honda duallies. My first street legal bike, besides a scooter, was a 74' Honda cb 360. It was my ticket to the world. I went everywhere on that thing. put almost 10k miles on it in about a year...this was in 2005. lol was a blast.

[@overlander123]

Nice job, breathing more life into the old XL.

[@johnatucker3]

I would love an ASMR video of this build; I’m sure it’s way too much production but Ari’s attention to detail is phenomenal.

[@599Honda]

Nice looking XL250. Not in the continental US, but good luck to the winner. I wish bike manufacturers would make something like this. Simple retro bikes = winner

[@richardorosso7377]

Totally in love with that bike.. great job!

[@johncaswell2648]

This video couldn't have been timed better. First weekend in June I'm picking up my dad's 1972 Kawasaki F9 350 Bighorn to begin fixing it up to get it back on the road. I've been doing a little prep work to get ready for it but I really want to get it running this summer.

[@roberthaldeman5312]

I had a 1974 XL 250 back in the early 80's. Fun bike it was allergic to water. I sold it and bought a DR 400 for trail riding. The person I sold it to still owns it.

[@chadkimmel8957]

She’s beautiful

[@Alien590]

The XL came out phenomenal! 👌

[@JerrySanders-dm9ys]

I have a 1974 Honda XL250 in its original configuration. I would love to do this to my bike.

[@FT__Motorcycles_Cars____-zg3fc]

foooooking hell man. What an incredible amount of work. Ari is so cool.

[@MarxOutThere]

This is so cool I might take one on myself.

[@Quatra05]

Wow, what an absolute beauty! I’m working on restoring an old CL125S - this video gives me so much motivation!

[@AriH211]

I'd certainly recommend the mo.unit for your project. It's a sweet piece of kit.

[@Guest-sl2qb]

My weekend watch 🎉

[@slappydave4241]

I was considering a vintage sport bike to fix up for track days as a mild restoration project Instead I just put an 87 FZ700 front fairing on my existing 2016 FZ07 track bike Less charming but achieved the fun of cobbling stuff together and having a weird bike lol

[@The77Game]

Great job. Only thing is i don't like the blinkers in the front and the rear light with the integrated blinkers. They don't really look like they belong on a vintage bike like this in my opinion. But other than that it looks amazing.

[@jlore6344]

That bike looks like it will be amazing. I agree with the other requests below that a Daily Rider episode with this would be great before it is given away to the winner (pick me pick me pick me).

[@Lemmings19]

Definitely a project of passion.

[@scottyd024]

What a build 👏

[@robertmoorhead3731]

That bike is so freaking cool now...

[@toddsorel-pg4hr]

I did a similar upgrade (but not nearly as thorough) to my 1972 Yamaha RT2 Enduro. I think this old Honda looks amazing and I would love to win it to sit next to my Yamaha.

[@travisc8771]

This is just in time for my xl75 I'm going to do up all fancy like.

[@edwinmaina458]

From Kenya 🇰🇪 Africa 🌍 loving the upgrade... It's a turn 🛞 of work 💪 but the end product is a load of fun 😊👏👏

[@Jimo368]

Great work!

[@n00bist723]

Kinda wild to me that the grand prize has both the xl250 and the trans alp. You'd think the trans alp would be split to the next prize (first place). Not to say any of the prizes are shabby just I'd think you would want to have the bike split up.

[@TK.CBF500]

Now imagine getting those mods to pass the restrictions in Germany (like MoT). But great bike build and nice result.

[@jacob14163]

Like the build. But for those complaining about the cost, you could similar build way cheaper. There's cheaper mods to use that still work great. Moto unit is just a big priced item, but is totally worth it. Most of that cost is for labor

[@gunnarimgarten2538]

Shoot, that ecu is dope. Didn’t think I’d ever go that deep rebuilding a bike, but that thing is just too cool. I foresee an expensive future for my 85 Magna😭

[@gunnarimgarten2538]

Sorry, DPU- power distribution unit. Not Electronic Control unit.

[@Barryferg100]

Nice rebuild. I had a 78 XL 350 that would have liked that treatment.

[@Bdub1952]

I wish I had the funds and talent to upgrade my 1973 SL350K2 like that. Great job, guys.

[@triumphbill]

It's beautiful.

[@PRSer]

Most of this video makes no sense to me because I don't work on my bikes at all. I send everything to the shop. It's still very interesting to watch and i quite enjoy it. I find it amazing that its possible to totally remake an ancient piece of machinery and bring it to the modern age.

[@louislesono]

Wish we'd see more of you harry,!

[@burhanmukmin5220]

SUPER COOL!! 🔥

[@CCitis]

Got 3 oldies in the garage at any given time. The issue is part availability! Can you get the right carbs, can you get an e ignition; etc etc etc. When you go to buy a vintage bike, check that parts are available.

[@AriH211]

That's why I love working on Hondas! Amazing how many OEM parts are still available. The gas cap and loads of rubber bits were all ordered direct from Honda.

[@CCitis]

@@AriH211 100 percent. I had a 71 CL450, pretty good to get parts. Currently a couple of old gals from the 80s and one from the 90s in the garage, they strike a nice balance between old school, with a few modern touches. Keep up the great content, see you on the road.

[@andyjdaviestjk]

Really nice job 👍

[@bryceh78]

Motorcycle of Theseus. While its a full update and restoration that looks fantastic, its not really a true 50yr old CRF 250 anymore either. If I win it I pledge to enjoy the hell out of riding it. 🙂

[@Nygle123]

I would love to see the in depth build process from this project.

[@davegoldspink5354]

Real shame living in Australia I won’t be eligible to enter this one. Love the work you’ve done on the bike. Can remember these XLs as a kid. Great job anyway Ari. 👍🏻👍🏻👍🏻

[@urbanstrencan]

Great video Ari, I am looking to restore the MZ ETZ 250, just got the bike now it's down to start tearing down :)

[@mgsxps]

I have a rough estimate of $2700 for part and supplies. Add labor and fabrication costs... I have no idea on that! I saw a Craigslist listing of a non-running ’76 XR-75 for $2500 (ooof!). So... bike + parts + labor = ≤ $10,000 value in this bike, plus the trans-Alp!

[@OG_Mereles]

I suppose you can always haggle and depending where you live get a better deal, but the official sweepstake site declares a total prize amount of ''$20,950'' only for the Heritage restored bike.

[@RStantun]

I'll have you know, that my 1979 XL250S is FAR more reliable than my modern CRF250L. I keep the carb empty between rides and it starts 2nd or 3rd kick every time. To be honest the clutch cable has just snapped but it had lasted 45 years!

[@mikeskidmore6754]

Sounds so Simple. I have looked for a long time for a an ignition kit to replace the points in my 1971 Honda SL 125 Motor. I had Powroll bore and stroke the SL-125 motor to 160 CC's Ported head hot cam and 24 mm Mikuni carb. I ran the stock ignition with a battery .. One day it lost spark . CDI kits for Honda SL-70's are a dime a dozen but I have not found one for the XL / SL 125 ect ..

[@carbq5280]

Used to have the same bike, had electrical issues, those old 6v systems are a pain the ass

[@wegert1]

I want that…

[@idancielers]

Oh my God it really beautiful 😍

[@CarlosGlatzos976]

So beautiful. Would be proud to own this gem. i'm turning 50 this year and always wanted a bike thats as old as me but even the worst bikes are several thousand Euros or more. But unfortunately I'm from Germany and can't enter the giveaway so I say Cheers and thanks for the great restomod.

[@smith0844]

Sweet

[@G3A3]

very nice indeed😃

[@sladewilson8241]

I would love to see full series of rebuild this honda

[@kensterling8628]

Thanks, that's a great video! Could you cover the installation of the Motogadget-mo...in detail? It seems it could save alot of bikes from being written off with hacked up wiring. Throw in the speedo, lights and pointless ignition....could you go further with some basics, like how to use a multimeter as you install this product. You might teach some, and get a few interested in electrical repairs. Great stuff as usual!

[@TacoedBars]

We need an ASMR rebuild video on this like the DT-1!

[@JDuBz815]

There are lots of new cruisers and even other bikes with tube type tires. Heck I've got cast, tubeless wheels on my bike but due to its odd tire size, I have run tubes in them if a tube type tire is what i have on hand. The point I'm trying to make is that going tubeless is completely unnecessary and can be expensive. That said, that whole bike was unnecessary and expensive. It's a neat little restomod featuring some pretty cool tech, but it would have perfectly fine for an in town runabout. Its got what? 30hp maybe? Not gonna gobble up a bunch of highway miles on 30 I wouldnt think. Ditching points for CDI ignition makes total sense and the carb replacement/swap makes sense too given the condition it was in. For reference, I have ridden dads old '76 TS125 on the street and it was perfectly fine. It's all original except for fuel tank cap, petcock, tubes/tires, battery, a fork service with new seals, and a few carb cleans over the decades.. used OEM Suzuki parts and the replacement fuel cap uses the original igniton key 30 years later lol. Drum front and rear brakes, tubes tires, original 40+yr old shocks and fork springs and points ignition/6V electrics.

[@kalaharimine]

Very Nice, i'm sure you'll get to the mundane stuff like a chain guard, plate hanger and mirrors.

[@hugoalju]

So... What I hear is RevZilla could have released a 90-minute-long episode showing Ari's skills and artistic talent, but they gave us only 8 minutes? Oh... You guys did us dirty...