CB250 Cafe Racer

wbrown343

RMS Regular
Messages
56
Drives
D2 S8
Thought id start a thread for my cafe racer project

CB250RS - condition awful, talk about regrets i have them but god loves a trier

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Beside my mates Suzuki GS650 that hes also modifying over winter!

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Got stuck in after a brief rip up the road the night after we got them home. Leaking oil got worse after getting a bit of heat into the engine, identified as a crack in the side cover. Took it off and found one of the coils was broken off the stator and after looking for ages for the right stator and cover, decided to buy a full engine which should be here on monday! Fingers crossed its not a lemon too :rolleyes:

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Bought a seat i liked the look of and cut my frame to suit using 2 90s and a length of 30mm pipe, i think its a nice proportion to the tank. Bought clip ons as well for the low, tucked front end style i think im going for

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Then decided the tank was too round so just cut the end off it to weld it up, was a small hole from rust at this end anyway so thought why not, worst welding job ever

Decided to plate up my frame instead of using the standard plastic mudguard, will seam seal before paint. Mini taillight recess welded in as well as mountings for my battery to sit under the seat hump

I wanted to mount my key and barrel in the frame so i designed and cut gussets at work to fit in the triangle of the frame! Unnecessary but i think they look cool and kinda retro.

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This is how it sits currently. Bits and pieces are away for blasting and zinc plating. Bought the 5 spokers as i kinda like the style of the 80s comstar wheels so ill have options on what to run as well! Will update this as i get more done

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Suggestions on colour for tank and frame etc welcome! Im thinking the same green as my s8 with matte black everything else
 

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wbrown343

RMS Regular
OP
wbrown343
Messages
56
Drives
D2 S8
Got my stuff back from blasting and got it primed and some of it painted. Meant to be matt black but every time i spray matt it ends up satin, havent quite mastered flash off times with it yet i think. Finish is ok but its a frame so not too worried about being absolutely mint! Excited for the build up stage now after i get the rest of the black sprayed and my other stuff back from zinc.

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Running clip ons so i took to grinding the handle bar mounts off flush, didn't intend on going right through but i think it looks really cool

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Spare engine landed and long story short ill be using my original with the stator and cover from the new one. The new engine had a helicoiled sump plug and there was dust inside the cam cover so thought it wasnt worth the risk when i know my original is a runner! Have resealed it and will be spraying black and changing some plugs and bits covers for either polished or stainless.

Thinking now on going goodwood green for the tank! Think a flat green would be more suitable to the age and style over the pearl racing green. Still undecided on which wheels to run so gonna spray them both so i have the option
 

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fabiostar

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970
Location
just over there.
Drives
...........
nice project and they are a good we engine but die without regular oil changes... cafe style? has to be spoked wheels for me im afraid. more in keeping with the cafe era.
 

wbrown343

RMS Regular
OP
wbrown343
Messages
56
Drives
D2 S8
Engine and few other bits painted last night, very pleased with the finish on the engine and the brake drum but definitely not matte black :joy:probably look better in satin anyway realistically

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Painted the spoked wheels as well but im not happy with the finish, they were a real curse to paint too, theres a lot of texture in the barrel of the wheel and thats the part of them you see so might end up sanding and repainting. Will order sprockets and tyres for them in the meantime, that might up the motivation to tackle spraying them again

@fabiostar agree on the spoked suits cafe style, i just really like the look of the comstar wheels. And definitely regular oil changes! The only filter is a mesh screen fitted inside the clutch cover so hoping very much that i wont have to split the engine again now after painting
 

roverspeed

RMS Regular
Messages
7,461
Location
Belfast
Drives
Insignia
Wow, one to follow.

I went to see A CBX250RS near Killinchy back in the summer. I wanted to do a similar project, but I found it to be an excessively big and heavy feeling bike for a 250. So I'm gonna hold out for a cg125 after Xmas. I want something super light and I'm not overly concerned about outright performance
 

wbrown343

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OP
wbrown343
Messages
56
Drives
D2 S8
Working away on this while waiting on bits and pieces coming for my car! Got my stuff back from zinc and blasting and very pleased with the finish even if i did forget a few bolts 🤦‍♂️ Parts Restore NI in Ballymoney if anyone is needing any plating etc. done!

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Tank will need a bit of filler work but good to get it primed before the rust starts on the bare aluminium - love the finish of bare primer

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Built up the front end and set the headlight and speedo in place just to gauge what they'll look like, very pleased with them. Thought it was actually gonna be too black until i built some bits on now im loving the look! Excited to see it with wheels on. Set the engine in last night as well which is where i discovered I hadn't sent 2 engine bolts :rolleyes: must get them left up some time for plating. Pleased with how it looks so far! Especially the clip ons which had to go above the top yoke to suit me

Next stage is try to get the twin calipers to work with my forks, this i'll need to modify my disks or get new ones with a lower offset and continue the build! Not particularly looking forward to the wiring but will be stripping it down to the bare minimum and hiding as much as a physically can of it
 

roverspeed

RMS Regular
Messages
7,461
Location
Belfast
Drives
Insignia
Really looking forward to seeing (and hearing) this once it's done.

I wouldn't worry too much about the writing, I imagine it's a very simple loom.

Are you gonna stick with the 2 into 1 exhaust or go duals?
 

wbrown343

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wbrown343
Messages
56
Drives
D2 S8
@roverspeed they actually come dual exhaust which is strange with them being a single cylinder engine but I've bought a 2 into 1 collector I was going to use. They say they lose a bit of power from exhaust scavenging but I doubt it'll have a massive effect!

A few bits and pieces done to this over christmas but no pics. Dual calipers are going to work out a bit of a headache. Does anyone know where I can browse bike disks by dimension? Struggling to find a 240mm disk with a lower offset to clear the fork legs
 

wbrown343

RMS Regular
OP
wbrown343
Messages
56
Drives
D2 S8
Plugging away over the holidays with this and the car! Car gets priority but this ends up taking more time annoyingly. Got a pair of straight Harley rear discs im going to try make fit my front, will be a bit of trial and error. Defo gonna be overbraked for a 250, they're 320mm :joy:

The comstars have been a bit of a headache to fit. Its a different axle same diameter front and then a heavier axle in the rear so I've had to modify my swingarm to suit the axle. Seeing the beefy tyres on the comstars convinced me that was the route i had to go, the tyres on the spoked wheels are tiny in comparison!

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Next problem is rear wheel alignment. Pic above shows 650 axle and spacer fitted to my swingarm which is obviously no good. Few adjustments to the hub should get me line with the sprocket and then hopefully close to in line with the frame. Stuck the tank and seat on for a bit of extra motivation!

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Looks quite cool in primer I thought! Be good to see the seat pan the same. Cut a couple of brackets for rear sets I got on eBay, seem reasonable quality but I'm sure they're not made to last. Look cool tho! Starting to take shape!

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variant

RMS Regular
Messages
1,630
Location
County Antrim
Drives
T5, Up Gti
The grey tank not make you think a nice coat of Morris Minor grey would look great with a subtle black honda badge

The spoked wheels would be my preference too but the comstars are far better now in black than I imagined

I've never had a motorbike in my life but I reckon a 125 or 250 like this will be my next midlife crisis once I get a bigger workspace.
 

wbrown343

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OP
wbrown343
Messages
56
Drives
D2 S8
@fabiostar Haven't been working on this much lately but unsure if the sets are actually going to work for me ^o) the clutch side is fouling on the stand so its gonna require a bit of rework on my brackets, might even have to incorporate the stand into my rear set bracket, I just need a spare evening to work it all out!

@variant Grey is a very common colour in a café racer is my only gripe! Gonna stick to my guns and go racing green to match my car. Absolutely do it, the brief spin I got on this before we stripped it would definitely put ya in the notion of getting the test. If I was doing it again id start with a 125 actually as well
 

noLUCKcivic

RMS Regular
Messages
917
Location
Lisburn
Drives
My Finger
I'm nearly 100% sure I was standing outside a chinese on the Longstone Street in Lisburn few months ago and seen this in the back of a pickup, must have been you couldn't be too many CB250RS in the back of pickups lol
 
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