Top End Engine Rebuild XR250R

This week on Weekend Adventure Rides Light Weight Adventure Bike Build we finish up the Engine Rebuild on the XR250R. Ill show you how to install the piston and how to time the camshaft along the way.
Parts:
Piston: bit.ly/39yc7is
Top End Gaskets: bit.ly/2OcJvUp
Instagram:
/ thatskent
/ wknd_adv_rds
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Song: JJD - Adventure [NCS Release]
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Watch: • JJD - Adventure | Glit...

[@Sachainterista]

Your videos are a treasure for XR lovers👌🏼👌🏼

[@antoniomodesto1157]

I have a 1991 XLX 250R with this RFVC engine. Only one mechanic in my town accepted to rebuild it for me.

[@stevenjohnston3328]

Hi from Aus, really enjoy the channel the content is gold for XR lovers & owners, wanting to get to know about rebuilding their own XR's... Such a great bike, I really like the idea of the CRF forks swap with the front brake etc. Awesome. Keep up the great work thanks for the great content....

[@krazed0451]

Stainless bolts into an aluminium head without anti-seize... Brave man :-)

[@WeekendAdventureRides]

I ended up putting antiseize on. But you are correct not a great idea to not use it.

[@robertmedford8430]

Thank you, I'm doing a crankshaft rebuild on my xr 250l so this video is extremely helpfull. Ordered the case splitter from your link.

[@Swimfinz]

Muchas Gracias! Great podcast! Keep up your yeoman efforts.

[@user-dk1dm2uk9h]

Thank you for the useful informations, I will use them for my ME08.

[@benyaminnaseri6612]

Very nice !

[@ralphbatts2702]

Your videos are excellent

[@savyourselffreedom2149]

Nice one man

[@riptwan]

I find it easier to install the piston in the barrel and then insert the wrist pin afterward - less chance of damaging a ring IMO, still a very well done walk through, thanks

[@ColtonRiffel]

Thank you!!!

[@aussiefarmer8741]

I'm guessing I'm the only 1 at this stage that noticed the 2 missing 6mm bolts on this side of the barrel missing. An easy oversight as he was filming and not walking around the motor. Im sure it got picked up later. Nice clean motor. Good job.There is just something about XR's is'nt there.

[@WeekendAdventureRides]

The bolts are in place! Yes you are correct I didn't notice them until I had two extra bolts left over! Glad they weren't something more important and easy to install.

[@gettingpast4391]

Reassembling my xr250 I spent an hour digging thru drawers, checking bags of parts and crawling around on the floor, sweeping out the garage, checking the driveway, looking for the missing WRIST PIN BEARING!!!ARGH! I finally gave up when it got dark, super angry with myself for somehow losing this critical part.....and then went to try to order one.... lol. You may or may not realize that the problem is.... 4 strokes dont use wrist pin bearings.

[@tomduffy5129]

Deffo need more subscribers

[@davidandrew3481]

Any XR lover would watch these videos

[@Jesseboucher541]

What’s the torque on the center valve cover bolt?

[@unclequack5445]

Did you go with the 280 cc piston kit?

[@niconine268]

Noice

[@pagas5002]

Well done but the only thing is in a 2stroke matter where the piston rings are because they may get caught in the ports but in a 4stroke does not matter because the will rotate in the cylinder while the e fine is working

[@MuhammadRizal-pz8mg]

Hopefully the knowledge will be useful 🖒

[@ofcboyd9253]

I don’t care for the edits … it’s like “poof” and we are here . !

[@WeekendAdventureRides]

I know what you are saying, but it's hard to film and work on the motor alone. Sometimes, you can't see what I'm doing, and instead of including that, it gets edited out. I'm continuing to work on my Videography skills. I appreciate the feedback

[@Whatever-ib6ve]

Thanks for your videos. Just pulled down my XR 250 1990 Rear shock and found the shaft is pitted. Do you know if there is a bolt in aftermarket replacement for it? Thanks heaps. CP

[@WeekendAdventureRides]

As far as I know there is not. I've read on forum that folks have used other XR rear shocks. Might be able to find a good used one on ebay.

[@user-iw3dd9xi4l]

Бро прокладка под клапаную крышку вроде идёт метал 'а у тебя паронит. Как себя ведёт паротит не сгорит?

[@nicyolo3906]

I've chancge head gasket and then when i put everything together there was no compression,can this caused because i put the camshaft lobes looking up when i timed it?

[@WeekendAdventureRides]

Either that or the piston rings are bad. But even with bad rings, you would have some compression. The air is escaping somewhere.

[@chowmurphy]

Just wondering if you have done a compression test on the motor yet, if so what are you getting for compression numbers much appreciated

[@WeekendAdventureRides]

I'll do one and post numbers

[@danstevens2204]

End gap. Piston ring end gap.

[@peteh6245]

Where did you get the stainless steel bolt kit?

[@WeekendAdventureRides]

Found it on ebay

[@johnpatacairk5510]

im having issues with getting my cam shaft on the timing chain. it just seems to tight any tips?

[@WeekendAdventureRides]

Make sure the chain is perfectly fit to the bottom gear, then make sure the chain tensioner is compressed all the way, now put the gear on with timing marks out and lined up with the top of the head, now put the cam in with the lobes straight down, put the bolts in the cam gear, now release the tensioner. If the timing marks are not perfectly level with top of head you need to move the gear on the chain.

[@WeekendAdventureRides]

Also make sure the piston is in top dead center

[@justinkairo4988]

I have a 2003 xr250r I’ve had for a while I can not seem to get it running. Me and a buddy who’s done more than a Few rebuilds took it apart to check it out and I kinda got scammed on it because the cylinder threads are stripped out and a bunch of other misc threads in engine. We checked the valve clearances and the timing seems to be right, carb should be good to go it’s definitely clean. It will not start we towed it behind. A vehicle in gear it just pops every like 15 revolutions or maybe more. It does have good spark what else could it be what do u think I should check?? Any help appreciated thanks!🙏

[@WeekendAdventureRides]

Check compression. Clean the carburetor. If you have spark and the timing is right, you only need fuel and air. As far as the cylinder head bolts I would use helicoils they work well and don't require an adhesive.

[@IIgorct347]

Bonjour, les couples de serrage sont en foot pound force (ft.lb) ?

[@WeekendAdventureRides]

Yes

[@CleanIreland-vg1jg]

Hi. Where did you gets engine parts? Are they new? Any chance to get any from Asia?

[@WeekendAdventureRides]

I try to get new parts when they are available. Unfortunately, some parts are no longer manufactured by honda. Parts came from OEM distributors online or Ebay.

[@markreiber4457]

What is the spark plug gap?

[@WeekendAdventureRides]

.028

[@jaimecalderon1340]

DO YOU KNOW WHAT IS THE CODE OF THE SWINGARM RECONSTRUCTION KIT IN THE ALL BALLS BRAND - FROM THE XR250-L FROM 91 TO 95

[@WeekendAdventureRides]

28-1021 it's the same kit as the xr250r

[@aguilaraguilar356]

Hi My friend which page you get The parts

[@WeekendAdventureRides]

Oem parts came from babbitt and Honda parts direct. Otherwise mostly ebay.

[@user-vt9uh7pt4j]

A question have the 84 XR 200 RFVC. Duel carb smokey on startup Suspect oil rings. And Valve stem seals have not rebuilt any 4 strokes is this the same engine only different displacement Cheers 🇦🇺.

[@WeekendAdventureRides]

The motor in the video is the 86-95 version. But the process is no different. If I were you, I would look online for a downloadable version of the shop manual.

[@harvybracamonte308]

Saludos desde Nicaragua. Podrias ponerle subtitulos en español a este video por favor. Gracias.

[@GordinJ]

I would love to see how he put the bolts into the cam sprocket.

[@WeekendAdventureRides]

I filmed it but you can't see anything. The cam chain tensioner has to be completely compressed and putting no tension on the chain. Put the gear in, then slide the cam in, put the bolts in that hold the gear to the cam. Put the bearings on the cam. When you release the tensioner the lines on the cam gear should perfectly line up with the top of the head. If they do not, check that you are at TDC and the cam lobes are down. If it's still not perfectly aligned you have to take it apart move a tooth on the cam chain in the appropriate direction.

[@andrewa765]

If I missed you saying it my bad but should you use locktite on every bolt

[@WeekendAdventureRides]

I do, on all of the case bolts. Just a drop

[@samboyd1646]

Does it matter what stroke top dead center is at?

[@WeekendAdventureRides]

Yes and no. If the cam and cam chair are attached, yes. TDC would refer to the piston being at the top of the stroke which happens 4 times a firing cycle. Cam alignment is more important, cam lobes should be down taking all pressure off the valves. You have the right combination when the piston is at TDC, camlobes are straight down and timing marks on cam gear are perfectly even with the head with full tension on the timing chain. Hope this is helpful

[@unclequack5445]

Bro, they were running it with no cam chain guide? no wonder you had to do a full rebuild.

[@eonblue46]

Great video! My XR engine is missing the receiver for the decompression cable on the cylinder head cover. I'm a little confused about what that receiver is doing because my engine seems to run fine without it. Do you have any insight to offer? Should I put a bolt in that empty hole or no?

[@WeekendAdventureRides]

Well it makes it easier to start the bike, which isn't a huge deal. But you have to put something in the hole or oil will pour out of it.

[@eonblue46]

@@WeekendAdventureRides Copy that - will do! Oil will poor out in general or only if the bike goes horizontal?

[@WeekendAdventureRides]

I read this again.. did you get it figured out? You are talking about the decompression cylinder which goes into the cylinder head cover? If it's not in, there's a hole in the motor. If you just leave the decompression leaver off it won't matter once it's started.

[@ElizaCoronelTV]

​@@WeekendAdventureRides what is the decompression lever even for? my bike is running but smokes alot any clue to what it could be?

[@WeekendAdventureRides]

@@ElizaCoronelTV the decompression lever makes it easier to Kickstart the bike by opening one of the exhaust valves partially.

[@rabbitohsrule121]

Great video, I have already rebuilt my 1984 xr250r engine the same way, however I later realised that the head is cracked and no good, I was just wondering what model is this engine you are rebuilding as everything seems to be the same as my engine, I have located a brand new 2000 model head which looks the same as mine in the description. Question is do you know if this 2000 mod head will fit my 1984 model engine? Any help is greatly appreciated. Thanks.

[@WeekendAdventureRides]

As far as I know the 84-95 are all the same and 96-04 are the same. I don't think they are interchangeable

[@rabbitohsrule121]

@@WeekendAdventureRides what is the difference between 95 and 96?

[@CleanIreland-vg1jg]

Rabbit, did you get the head? How is it? I am looking at the 1987 xr250 but worrying about parts availability. Maybe in Indonesia they have some?

[@rabbitohsrule121]

@@CleanIreland-vg1jg Not yet mate. I now have a 2004 XR 400R But I have located a complete head of a later XR 250R that I am considering. Parts are very pricey for these earlier model XR'S! Good luck with it.

[@sanjaypradhan1719]

What is the exact year of this xr 250r

[@WeekendAdventureRides]

1995

[@ralphbatts2702]

Timing chain noise how to adjust

[@WeekendAdventureRides]

Give me a little more detail. Is the chain new? Is the drive gear damaged? Do you have the chain guide in correctly? Is the cam chain tensioner tight on the chain? Is the piston in TDC and the cam gear timing marks perfectly even with the top of the head?

[@danielheilker2970]

What year is this motor?

[@WeekendAdventureRides]

@@danielheilker2970 94

[@gabrielvictor7781]

Great video, planning to do the same fairly soon. Very helpful! How did you get the case so shiny?

[@WeekendAdventureRides]

Used a bench grinder with a fine wire wheel

[@menehune87]

@@WeekendAdventureRides Can you even do it with a new one? I will buy a XR 400 from '99 and the motor was renewed. I love the metallic look of your crank case. Can I make my new crank case ( painted ) the same way shiny and vintage? Thank you. Your videos are awesome 👍

[@WeekendAdventureRides]

Yes sir. It's all aluminum so you won't have any problem getting it shiny after the paint is off

[@menehune87]

@@WeekendAdventureRidesThank you very much! I love your XR series. Can't wait to get mine:))

[@evertvizcaya3080]

Yo tengo una consulta una moto Honda R250 y tiene malo el silindro soy d Nicaragua y lo nesesito

[@WeekendAdventureRides]

Can you have the cylinder machined? Maybe a new piston?

[@hasinthaheshanweerasundara2608]

my xr250s head is some what a little damaged so can i replace the head or will i hav to replace an engine

[@WeekendAdventureRides]

You can replace just the head. What year is your bike?

[@hasinthaheshanweerasundara2608]

​@@WeekendAdventureRides 1997 both kick n starter

[@WeekendAdventureRides]

You will need the head off a 96 to 04. They are fairly abundant so shouldn't be too hard to find

[@hasinthaheshanweerasundara2608]

@@WeekendAdventureRides im having a thought on replacing the engine so it'd be like a pure beast

[@WeekendAdventureRides]

My suggestion would be in that case to order the big bore kit either 280 or 300. You will have to rejet the carb. If you want it to be fully maxed out open up the airbox and run a full after market exhaust. Most of those parts are available from "XR's Only"

[@seniormechanic4555]

I planning to get xr250r with the same engine, what is the difference between the oil pouirng in the crank case or in on top of the frame near the gas tank? Is this type of engine is dry sump or wet sump? and what is the year of this engine, i will get xr250r with this engine and its says its 1996. Please help me!

[@WeekendAdventureRides]

This engine is a 1995 and the last year of the oil being completely stored in the crank case. In 96 they did a complete redesign with oil being stored in the frame. Oil stored outside the case means it generally runs cooler. The mechanics of the engine are not very different.

[@seniormechanic4555]

@@WeekendAdventureRides Thank you man, appreciate it!

[@snxwbear876]

man, I hope I have that kind of engine:

[@WeekendAdventureRides]

Tell me more

[@snxwbear876]

wdym sir?

[@WeekendAdventureRides]

We're you trying to identify a motor?

[@snxwbear876]

well I have an old xr200 and I'm so amazed how powerful your xr250 engine is:

[@patrickjones1061]

Very informative. You don't need to set the valves?

[@WeekendAdventureRides]

I will during an upcoming video

[@patrickjones1061]

@@WeekendAdventureRides Thank you for your video series!

[@jasoncrowley4870]

​@@WeekendAdventureRides is there a video posted yet for the valve clearance.

[@rafaelescobar5775]

Donde puedo comprar todos los sellos para el motor xr250r 1986???gracias

[@WeekendAdventureRides]

I got mine from an oem distributor. Such as Honda Parts Direct. You may also find them on ebay

[@rafaelescobar5775]

Ok. Thanks..

[@anishranjit6073]

i ve 1994 XR250R RFVC ENGINE BT I NEED ENGINE PARTS WHERE CAN I FINE HELP ME ON THIS 🙏

[@WeekendAdventureRides]

I get them directly from oem distributors. It might depend on what part of the world you are in as well. Ebay has lots of parts too.

[@WeekendAdventureRides]

Search oem honda motorcycle parts and you should be able to narrow your search from there

[@kayakmc7]

Did not show the difficult parts, installing 2nd circlip and piston into cylinder.

[@WeekendAdventureRides]

Maybe I'll include that in the bloopers reel at the end of the year.

[@redblazehorse]

You didn't show adjusting the valves before you put the covers on.

[@WeekendAdventureRides]

You are correct. I'll be making a separate video on just that.

[@MarcosGarcia-vj1hw]

This guy sounds like Seth rogan

[@AIRPORT-mc2ys]

0;43 HARDENED conrod small end with HARDENED gudgeon pin is BAD DESIGN. honda designed that WRONG as the small end SCORES.

[@lynnmcintosh-gc7jt]

it doesnt help when you skip steps it doesnt say anything about whats going on with the bottom of the chain or show how you put the piston in with the ring compressor

[@WeekendAdventureRides]

I didn't use a ring compressor, i would suggest it though would have made my life easier. The timing chain rides on a sprocket. You just line the teeth up on the chain

[@markcastilloumalichannel1488]

Hi sir im from philipines how to order a overhaul gasket for xr250r?

[@WeekendAdventureRides]

You would have to do it through an OEM distributor