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XT225 Resto / recommissioning #147814 04/26/20 03:06 PM
Joined: Apr 2020
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Lobby Offline OP
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Well, after years in the shed it's now time to bring back the Serow!

It was in quite a state.....

[Linked Image from i.ibb.co]

[Linked Image from i.ibb.co]

[Linked Image from i.ibb.co]


She looked a bit better after an initial wash.

[Linked Image from i.ibb.co]


Tank, side panels and seat off.

[Linked Image from i.ibb.co]

I gave the engine a bit of a degrease and clean, it didn't come up too bad

[Linked Image from i.ibb.co]

[Linked Image from i.ibb.co]

Right, now for the bad bits.....

New battery required (obviously)
Leaking fork seals
Petrol tap leaking
Service required (oil, plug, oil filter and air filter)
New tyres and tubes required
A fair bit of rust inside the petrol tank.
Reserve filter on petrol tap has disintegrated (new taps are no longer available so I'll have to live without this and just run an inline filter before the carb)
Exhaust silencer has rotted out so a new exhaust is required.

A few bits of good news......

The brakes still work (not seized at least)
The screws in the master cylinder lid came out without rounding off.
The bleed nipple on the brake caliper loosened up ok.

Next weekend I'll use some electrolysis to rid the tank of rust, I've already made a blanking plate for the petrol tap and an insulated anode). If I have time then I'll remove, strip and clean the carb. Once the fuel system is sorted I'll do the service and check that the engine runs ok.

I do have a few questions that I wondered if anyone can help with: firstly, what is the colour / paint code for the dark grey frame as I'm going to have to spray it in a few places where the rust is starting. Secondly, I'd like to retain the original seat cover but it looks stained / discoloured, is there anything that works on restoring / cleaning the vinyl?

[Linked Image from i.ibb.co]

Thanks for reading and stay safe everyone!

Re: XT225 Resto / recommissioning [Re: Lobby] #147821 04/27/20 05:15 PM
Joined: Dec 2019
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JPouchet Offline
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On the exhaust - check out Delkevich, available in the UK. There was a discussion thread here Delkevich Exhaust

Be careful with cleaning products on the seat. I'd be worried anything with bleach would ruin the color. Perhaps some automotive vinyl restoring / cleaning products and a lot of elbow grease.

JP


Adding some Adventure to my life. Orange County, CA
'07 XT225
Re: XT225 Resto / recommissioning [Re: JPouchet] #147826 04/27/20 08:04 PM
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Originally Posted by JPouchet
On the exhaust - check out Delkevich, available in the UK. There was a discussion thread here Delkevich Exhaust

Be careful with cleaning products on the seat. I'd be worried anything with bleach would ruin the color. Perhaps some automotive vinyl restoring / cleaning products and a lot of elbow grease.

JP






Thanks for the exhaust info, I was wondering if something from the marine industry would work on the seat as a lot of boats use vinyl on exterior seating......

Re: XT225 Resto / recommissioning [Re: Lobby] #147871 05/03/20 07:36 PM
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I managed to get a new petrol tap filter from Ebay, heater it in some boiling water to soften the plastic and it fitted a treat.

[Linked Image from i.ibb.co]


I stripped the carb down, the fuel in the bowl was like treacle! The float needle valve and seat were completely stuck in place and needed a lot of work to free up! I cleaned the carb and blew it through with my air line and it's now back on the bike, I did notice that the intake rubber between the carb and the engine is starting to crack and perish so that will need replacing but it's not cheap!

The worst thing I found this weekend was that the front rim has corroded and split...... this will need a new wheel will have to specially built as there don't appear to be any secondhand wheels for sale. Expensive frown

[Linked Image from i.ibb.co]

[Linked Image from i.ibb.co]

Re: XT225 Resto / recommissioning [Re: Lobby] #147877 05/04/20 05:31 PM
Joined: Dec 2019
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JPouchet Offline
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Ouch! Seen that on many bicycle wheels but rarely on motorcycle. Would think someone applied too much tension to try and true the wheel sometime in the past. Can take years for the strain to build to the cracking point.

Good luck with the wheel build. At least it won't ever need attention, short of wheel bearing grease, again

JP


Adding some Adventure to my life. Orange County, CA
'07 XT225
Re: XT225 Resto / recommissioning [Re: Lobby] #147879 05/04/20 06:40 PM
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Az4x4 Offline
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Originally Posted by Lobby
.....The worst thing I found this weekend was that the front rim has corroded and split...... this will need a new wheel will have to specially built as there don't appear to be any secondhand wheels for sale. Expensive frown

[Linked Image from i.ibb.co]

[Linked Image from i.ibb.co]..

That's a shame. Time, spoke tension and corrosion did the job on it. Don't give up just yet in your search for a used replacement wheel. No idea what you'll pay for a new wheel to be built, but a used replacement wheel should be less expensive if one can be located. Best of luck sorting that problem as your work on the bike progresses..


..I'd rather have questions I can't answer, than answers I can't question.. Dr. Phil
Re: XT225 Resto / recommissioning [Re: Lobby] #147880 05/04/20 07:11 PM
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Selden Offline
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There is a front wheel (complete with rotor, but missing two spokes) for sale on eBay for $140

https://www.ebay.com/itm/03-07-YAMAHA-XT225-FRONT-WHEEL-RIM-MISSING-2-SPOKES-21-21-INCH-ROTOR-OEM/254587388668?hash=item3b469742fc:g:M4gAAOSwLg1er5P~


Don't fix it if it ain't broke, don't break it if you can't fix it.
Re: XT225 Resto / recommissioning [Re: Selden] #147960 05/13/20 08:32 PM
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Originally Posted by Selden
There is a front wheel (complete with rotor, but missing two spokes) for sale on eBay for $140

https://www.ebay.com/itm/03-07-YAMAHA-XT225-FRONT-WHEEL-RIM-MISSING-2-SPOKES-21-21-INCH-ROTOR-OEM/254587388668?hash=item3b469742fc:g:M4gAAOSwLg1er5P~


Thank you, I live in the UK and the shipping cost and customs charges are quite expensive.

Re: XT225 Resto / recommissioning [Re: Lobby] #147961 05/13/20 08:44 PM
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I needed to sort out the rust inside the tank so used electrolysis as it worked well on my TZR250.

[Linked Image from i.ibb.co]

[Linked Image from i.ibb.co]

[Linked Image from i.ibb.co]

[Linked Image from i.ibb.co]


Next up, I cleaned and scrubbed the fork gaiters, they came up pretty good. One less thing to buy!

I serviced the bike (filters, oil and plug) but it took longer than it should have as the drain plug bolt head rounded off, I can't believe how tight it was. Not sure if this is a common problem? I also fitted the new battery.

Next weekend I'll refit the tank along with an inline filter and new fuel line and hopefully she'll fire up for the first time in years smile.

Re: XT225 Resto / recommissioning [Re: Lobby] #147962 05/13/20 09:06 PM
Joined: Aug 2008
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Az4x4 Offline
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Wondering what you ended up doing about the corroded and split front wheel rim. Hopefully come the weekend she fires up and runs just fine. Would be ideal if that's the outcome you get. Best of luck as your restoration project proceeds..


..I'd rather have questions I can't answer, than answers I can't question.. Dr. Phil
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