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Aussie SRV250 Restoration Project
#1
I purchased a well used Yamaha SRV250 for a project bike three months ago and two months ago I started restoring it. The project is almost completed now with just some paintwork & minor details to finish but I thought I'd detail the process I've been through here.

This is the bike as I purchased it.

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The bike had some accident damage on the right side and was fairly weathered from 20 years of use.



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#2
I started the restoration process by removing everything from the steering head forward:-

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The gauge covers were replaced and new instrument damper rubbers fitted.

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The lower fork legs were hand polished.


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The front hub & spokes were repainted.

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New Bushes & seals were fitted to the forks, the front brake caliper was overhauled & a new disc fitted. The speedo drive was replaced and a new speedo cable fitted. New inner & outer headlights rims were fitted, one indicator lens was replaced, new mirrors were fitted and the brake master cylinder overhauled. The triple trees were repainted and everything else was cleaned & polished as required before being re-assembled.

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#3
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The brake mastercylinder, bar end weights & clutch perch were repainted with gloss black enamel and the handlebar switchgear was touched up with satin black by brush. New handlebar grips and a new brake lever were fitted.

The carbies were removed, stripped down, thoroughly cleaned and re-assembled.

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All of the exhaust components were thoroughly cleaned and polished.

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The engine was removed and thoroughly cleaned before removing all of the external casings.

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With the engine removed the engine bay was thoroughly cleaned.

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The engine was then prepared for painting and masked up.

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#4
I used Dupli-Color engine enamel to paint the engine, first giving it several coats of primer.

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Followed by several coats of Aluminium engine enamel.

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All of the external engine covers were then polished by hand.

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The covers were then re-fitted along with a new set of intake manifolds.

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#5
A new rear mudguard was fitted & the rear wheel, swing-arm & shockers were then removed.

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The swing-arm, side & centre stands etc were then prepared for painting.

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The swing-arm was painted and refitted along with a good used set of rear shockers that I bought from Japan.

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The rear wheel was in far better shape than the front wheel and only required a good clean & polish. New rear brake shoes were fitted along with a new rear sprocket.

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The side & centre stands were painted with gloss black enamel & refitted.

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The engine was then refitted.

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#6
I still have to get the front mudguard and exhaust/footpeg hangers repainted but I am having difficulty finding somebody local that can match the Empress Maroon paint.

I decided to temporarily fit the tank, seat, side covers & exhaust to see what the project was looking like overall:-

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I still have to paint and fit the number plate bracket and fit the drive chain but I will have plenty of time to do that while I'm waiting for the mudguard & exhaust brackets to be painted.
#7
Welcome to the forums and thanks for the great post.

Beautiful restore. Can't wait to see the finished product.
#8
(06-30-2015, 08:57 AM)Chief_Mechanic Wrote: Welcome to the forums and thanks for the great post.

Beautiful restore. Can't wait to see the finished product.

Thank you for the welcome and your appreciation of my efforts. I too cannot wait to see the finished product and I will post pictures of the completed project here as soon as the job is done.
#9
After three months this project is finally completed with the bike being registered on the road yesterday.

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