Project RS250 Rebuild

[Mick]

So after months of putting it off and the fact I like riding the one bike I have, Ive finally decided its time for the rebuild. My initial intentions are just to give it a good clean up, rebuild the top end, and replace any other parts I feel are needed at the time. Where that stops Im unsure, but time will tell.
This will be my first mini project on bike so lets see how I go.
Here is my progress from today

How it starts


Fairings and tank off


Both Barrels off and coating is still in great condition

[Loud]

Oooo, a fellow RS250 rebuilder! Good luck with it mate, I'll be watching with interest. Mines the "Awww it's broken" thread below.

[Mick]

Thanks mate, Ive been through yours already.
Lets see where this so called "rebuild ends"? Already thinking of levers, rearsets, frame polishing, sand blasting of pipes, braided brake lines, and a possible respray. I suppose one thought just leads to another. haha

[Loud]

Reckon a set of clip ons would have to be factored in too, the stock ones are fugly!

I'm looking to place several orders in a week or so, we can save on shipping if you're ready to order by then too?

[Commander Keen]

Put a TSS 500cc stroker in it, oh please do..

[Mick]

Sorry Loud, youre a head of me.
Commander, I think the TSS500 is an urban myth. haha

[Mick]

I've decided to respray and have organised a spray painter and just ordered the decal kit.
Im going for this

[rgvlee]

Gee that's a shame, the blue/yellow rossi scheme you have is one of the better ones.

[SP1RITED]

My 2c, I have the Rossi 2001 with Yellow accents. . . but the Chesterfield getup is cooler

[Mick]

I like the chesterfield more myself. And in three years time all of a sudden I dont like it, it can always be redone.

[Mick]

Today I took to the fairings with a heat gun and WD-40 to remove the decals. Came off very easily using this method, then used turps to remove the residue left over.

Now Im ready to start the sanding.

[Loud]

Now Im ready to start the sanding.

So the "possible respray" goes straight to the top of the list?

[Mick]

It did when I found a mate who offered his skills for beer.

[Mick]

Can anyone tell me if there are indicators in the street tyga kit tail light? Otherwise what have others done to install them?

Thanks

[shaynoinsano]

good to see another rs rebuild going on..
i'm just about ready to put all mine back together. i got a heap of pics in the steps, ill put it all up on here after its done.
Can only get on here every now and then, since work has gone crazy..

good luck with it all, you should end this project with a dyno print out :-)

[Spiren]

Mick the tyga kit dosnt come with indicators (or so im told) there is a company on ebay called south sydney motorsports. who do led indicators. problem is you have to install flasher relays all up should be about $100 for one set rather expensive they have a few styles iv just never got around to doing it. hope that helps

[Loud]

I reckon the shape of the indicators from the '08 RS125 would suit the Tyga kit perfectly - 4 orange LEDs with a clear lens. They're available fairly cheaply from eBay new and second hand too - add an LED flasher unit and you're away.

...Sure you want to lose the original fairings though? Desmo will kill you

[Mick]

I found out from Tyga that you can use the standard tail light setup with their kit, so Im thinking I'll use mine tail light and just get clear (bulb) indicators.

Loud,
Im not a fan at all of the front of the Tyga kit, but love the single piece rear cowl. I can also get rid of those bolts for the rear seat.

[Mick]

Ive slowly just been pulling apart then cleaning as bits and pieces arrive.
How it looks now.


Can anyone tell me if this hose needs to be this long? Its sits between the Carby and Reed block.



Thanks

[rgvlee]

That hose acts like a boost bottle, if you shorten it you will lose bottom end.