After getting my recently-acquired '93 XR250L bike up and going (thank you for helping me with the high idle issue on another thread), I had an oil burning problem after riding it 70 miles. I decided to go ahead and have it fixed locally. I dropped it off Monday, and by Tuesday the diagnosis was the cylinder had witness of water/corrosion in the cylinder. Pictures I took show about 3/4inch of witness mark of waterline along one side.
So, I had XR's Only send me by Overnite a JE 10.5:1 76mm (+3mm) forged piston kit, valve stem seals, timing chain, top end gasket kit, etc. More than $300 of parts. OK so far...
Parts come in ... then local machine shop decides they cannot get bore/honing done for 2 weeks. So ... I bring it back to my shop and bore it on a verticle mill, then hone it. Finished 10:30pm last night. Drop everything off to the mechanic this morning, confirm the bike will be complete by 6pm tonight so I can do an all day ride Monday in the Smoky Mountains. Get the bad call that the piston wrist pin is seized to the conn rod; took heat and pressure to remove it. Conn rod needs replacing. BUMMER .... very bummed.
So Hot Rods Crankshaft company makes a conn rod kit for this engine for $150. Local mechanic will need another $300 in labor to R&R the conn rod. That $300 is in addition to the $500 in labor for the top end job. Add another $200 for various surprises TBD, and I am at $1000 in labor, $450 in these parts.
Plus, I have purchased:
NOS parts, $280
- NOS LH side cover in '95 uranus violet
- Good used RH side cover, and paint to match
- NOS fork boots, uranus violet
- NOS Hand guards, white
- NOS headlamp decal, uranus violet
- a bunch of misc stuff adding up to a several hundred dollars like new Throttle cables, NOS air box cover, air/oil filter, Keyster Carb kit, replacement turn signal, $300+
- custom machined billet steel clutch perch (fun)
- 250R exhaust system to replace the 250L system, $200
- 12T front sprocket, RK chain, 44T rear sprocket ... all brand new $125
- NOS owners manual, NOS service manual, $70
My neighbor, who bought this bike and its twin brand new in '93, sold me this bike with 1,040 miles for $650 with the condition that I could return it if it was too much of a project. This bike was stolen from his last residence in '04 and recovered in '10, missing the side covers, air box lid, broken clutch cable perch, and looking rough as hell.
I was OK with investment until the cylinder was found to be bad. But I sucked it up thinking I would have another $1000 in this bike that is probably only worth $1500 in decent running condition before adding the NOS parts. Now, I will be into it at least another $500, with an unknown situation on when the spending will end. After I cleaned it up over the course of a day, other than a dent in the fuel tank, the bike actually looks very nice as is - before installing any new parts.
What would YOU do in my situation?? This is my first XR, and I don't know when the spending will end for this old girl
1. return the bike back to my neighbor in parts, and eat the 400-500 labor bill, sell off the new parts on ebay that I cannot return to the vendors
2. suck it up and continue to throw money at it until it's done
3. any other ideas???
To make it worse, I went ahead and invested in a 34mm throttle body and fuel injection system, with plans to FI the bike. And then add the 34mm turbo charger I have new in the box for another bike project. I thought this would be a fun and unique dual sport machine with lots of low end torque for the mountain riding here in East Tenn. These pre-'96 XR250 engines don't have much in the way of performance aftermarket parts available - cams, stroker cranks, etc. Even finding a good exhaust is a difficult. But because I like the light weight of the 250 versus my riding buddy's XR650L heavy bike, I figure there aren't many options unless I go with the CRF230L or another brand and model. I like the XR styling better than the somewhat generic looking CRF styling.
I look forward to your advice.
Bummed out in Tennessee
Edited by keisler, 25 May 2012 - 04:06 PM.