Yamaha RD250E "Coffin" Restoration

[D.J]

This is how I received the old girl, functional (except for the front brakes, thanks to a vigilant previous owner who sprayed CRC over everything to protect it , and I am thankfull he did ).



I will try to document the resto, this will be a full teardown luckily the support world wide for these bikes is complete, looking at the paperwork the bike has had 1st oevrsize pistons installed and new conrods and bearings, teardown should be interesting.

Well the teardown started over the last few days and a fair assesment of the parts and work required was undertaken. Luckily the wheels, clocks and electrics are in good condition main things that will be hard to find are headers and pipes (if anyone has a set of expansions they would like to sell, let me know , even if you have a nice set of OEM silencers for it).



Marking all the parts correctly is vital



Fork tubes need replacing or re grinding and hard chroming but buying new might be cheaper than re grinding, I have found a supplier in England;



Engine has been freshly rebuilt and is just in need of a cosmetic resto, just need to blast and not get any media into the important parts



As we are now with still lots to go.



Parts list ordered so far

Stainless bolt kit
Full rubber kit
Pattern Mirrors
NOS front mudguard
Patten grips
Swingarm bushes
Oil and fuel line kits
New lock tabs for sprockets and swingarm

Will update when I can but will be away from the bike for two weeks.

DJ

[Geeza]

omg it's naked now!

[dennisw]

Nice one DJ can't wait to see,i must pull my finger out with the ZXR.

[Geeza]

Nice one DJ can't wait to see,i must pull my finger out with the ZXR.

[D.J]

It will get a few mod cons like tapered roller bearings in the headstock and braided brake lines as well as the usual complete going over, the idea is to make a new bike out of it. ( well as new as possible anyway).

[MattyA]

man it looked pretty good to begin with, good find!

il be watching this space.

[MattyA]

what year is it? and do you know the paint code? it has the same scheme as my ty.

[D.J]

it's a 78 and the RD guys use Ford Diamond white as the correct colour. will have a look for the paint code.

This is fron the RD forum

1732 36/W Clean White RD RD250/400E 1978.

[MattyA]

cheers mate, im gettin my bits painted this week and you have saved me some dicking about! same year as mine so i reckon it would be the same.

[brethren22]

nice one Redrider! it's uncanny how close my 400 looks to this. must share lots of common parts

who did you find the fork tubes through in the UK? i'd like to compare prices with the ones i've seen in the US. given how straight it all is, i'd say you'll have no trouble getting this thing back to better than original state!

[Lorenz]

Cool project - looks awesome...
They got the cafe styling and lines so right out of the factory with these I reckon.

[D.J]

nice one Redrider! it's uncanny how close my 400 looks to this. must share lots of common parts

who did you find the fork tubes through in the UK? i'd like to compare prices with the ones i've seen in the US. given how straight it all is, i'd say you'll have no trouble getting this thing back to better than original state!

I have been watching your thread with interest , yep 400 and 250 were identical except for engine( longer stroke, bigger barrels and primary drive) and exhaust. Am looking at putting the 350 barrels, oil pump and exhausts on it.
Even better is a supplier I just found in Australia $276 for each tube although they say the 400 and 250E ones are 34mm and they should be 35mm X 543mm.

http://www.motorcycle-parts.com.au/3...Fork_Tubes.pdf

This is the UK supplier but I havent had a price yet

http://www.staniforths.co.uk/catalogue/Suspension.pdf

Cool project - looks awesome...
They got the cafe styling and lines so right out of the factory with these I reckon.

Agreed Classic Cafe I think

[brethren22]

I have been watching your thread with interest , yep 400 and 250 were identical except for engine( longer stroke, bigger barrels and primary drive) and exhaust. Am looking at putting the 350 barrels, oil pump and exhausts on it.
Even better is a supplier I just found in Australia $276 for each tube although they say the 400 and 250E ones are 34mm and they should be 35mm X 543mm.

yeah they're bloody expensive! i'm looking at picking up a bunch of stuff from HVCC in the states. they sell the tubes at US$260 a pair

Suspension

mine are definitely 34mm, are yours 35mm? if you're keen on trying to save some cash on freight we can always combine shipping to sydney and i'll send them on your way when they touch down. sydney to perth isn't too bad for that sort of size and weight

i'll probably be picking up a bunch of stuff from them in the next couple of months so let me know if you're keen. or if you find a better deal!! oh, and if you see anything coming off my bike that you need give me a shout

[D.J]

260 a pair sounds good, mine are definately 35mm, seems like the Daytona ones will fit. I think they changed for the E model 250 and 400, would be interested in shared freight for sure.

Let me know if you are getting rid of your headlight ears , Oh and did you find a good source for the exhausts?

DJ

[brethren22]

^alright mate, i'll keep you posted and maybe you can do the same. when are you looking to buy?

i'm guessing that the 250 took on the 35mm legs at the same time that the RD400 did which would have been E Models in some countries

[D.J]

Bike is just about fully stripped now, just the swingarm to come off and off to the powdercoaters it goes. With some other bits.



One Fork has come apart nicely seems it has been fitted with progressive rate springs at some point in it's life.haven't started the other one yet.



Engine casings have been sandblasted while the motor was sealed as it has received a bottom and top end rebuild recently, lots of care was taken to not get sand where I didn't want it.



Parts are starting to arrive , lots of rubbers, mirrors,35mm fork tubes, couple of special tools,stainless bolt kit, correct period oil,fuel and drain lines, pattern front mudguard.

Unless it's VGC it will be changed.



The missus made me put the tyres from the ute in the shed so I thought they might make a good base for the sandblaster.



Parts are coming along ok before etch priming and painting



the frame will go away and I can get to restoring all the parts, will have to catch up with Mr Potato about the tin ware paint.

[MattyA]

lookin good mate. i like the blasting cabnet. my front lawn is still pink with garnet.

[D.J]

I went with the very fine glass beads when blasting on this one matty as most of my blasting will be alloy, fair bit of work in blasting the frame and swingarm so may leave that to the experts.

[D.J]

Frame is back from powder coating, need to tap every thread and remove some from the usual places. The guys at Southside did a great job on a day and a half turnaround, more bits to come back are battery box, rectifier plate, headlight shell, and top yoke.

[melbxs]

Nice to see an RD going back to original rather than it being butchered.

Looking forward to seeing it in all it's glory.