Emergency Refueling And Trying Plastic Welding

This week, I ran out of fuel just before payday so I tipped some fuel from Rosie’s tank into a fuel can to refuel Sylvie. I also tried out my plastic welding kit for the first time.

I captured all the action on video – here’s the vlog:

The refueling comprised getting fuel out of Rosie’s tank into a fuel can, which proved harder than expected.

I eventually just poured the fuel out of the top of the tank.


I refueled Sylvie from the fuel can and promptly hit reserver again on the next day’s commute.

I filled up the fuel can again the next time I took my car out so I could get to work again without needing to completely fill the tank before the Christmas/New Year break.

I decided to try out my plastic welding kit on one of Erica’s side panels, as I hadn’t used it yet. It turned out pretty well for a first attempt.

I also found out that the clutch switch only stopped working again during the heavy rain we had last week and worked fine again once it had dried out, so replacing it is no longer quite as urgent.

That’s all for this week’s update – I’ll see what I can fit in over the next week. In the meantime, Merry Christmas to those who celebrate it, and Happy New Year to all!



Stopping Sylvie Stalling And Securing Shrouds – Fixing CBF250 Clutch Lever Detection

This week, I finally had time to spend on working out why Sylvie’s clutch lever switch hadn’t been working and secured the left front tank shroud fairing.

Here’s a video of the process:

I started by checking the switch to see if it was sticking.

Next I removed the lever and checked the swtich .

I then removed the switch and cleaned it with elctrical contact cleaner.

After a fair bit of testing, I found the issue was caused by the lever not allowing the switch to fully extend.

I put the lever in my trusty bench vice and used a trinagular file to put a small groove in the lever to allow the clutch switch to extend fully when the clutch lever is engaged.

Testing was a success, so I moved on to finding a replacement for a missing bolt for the the left side tank shround fairing.

That’s all for this week’s update

Apologies for the quality of some of the photos, I wasn’t aware that the GoPro had a terrible angle and didn’t take any other photos at the time. I’ll see what I can come up with for next week’s update and will try to remember to get more still photos just in case!



Wiring Up Sylvie For Trickle Charging And Picking Up A Plethora Of Parts

Because I’ve been using the heated grips a lot more now that the frosts have started and have a fairly short ride to and from work, I decided to fit some wiring to allow a trickle charger to be connected in order to prevent a flat battery recurring in the dead of winter.

The trickle charger had a connector on the charge cable where the clamps connect.

I found a jumper cable that uses the same style of connector at my local electronics store.

I bought a couple of crimp connectors while I was there

I cut the cable in half, as I might be able to use the other connector later.

I stripped the ends of the wires and crimped the connectors on.

I took Sylvie’s seat off and found one of the reasons I’ve had trouble getting the clips that hold the sides on in the right place when putting the seat back on.

I trimmed a little triangle out of the top layer of padding.

I took the left side panel off to get to the battery.

Once the side panel was off, I attached the new cable.


The side panel went back on and there was hardly a trace of the mod.

I connected the trickle charger and the expected lights came on before I plugged it in, indicating both that the polarity of the cables was right and that there was still some charge in the the battery.

I then switched the charger on and made sure the battery was charging. 

I also made a day  trip to Sydney to pick up some CB250RS parts and a spare swingarm for Sylvie that a friend from the 2fiftycc.com forums I’ve traded parts with before had brought with him while he was visiting Sydney for other reasons.

The swingarm came with the wheel mounts and chain adjuster plates

This rack was custom-made to fit the a CB250RS, so hopefully I’ll get one of them road-ready again over the winter and I can use it!

The parts included a full set of original indicators, a brand new inner tube still in the box, a mirror, several 50 master chain links and an assortment of brackets and clamps, including the original headlight mounting nuts, which will be very useful for restoring the original electrical connections on Erica’s headlight!

That’s all for this week. Hopefully I’ll have some new brake pads for Sylvie soon!

Sylvie Loses A Footpeg Cover But Gets Some Other New Parts

This week, I noticed something amiss on Sylvie’s left footpeg. The rubber cover had come off completely and gone missing somewhere!

The right footpeg was normal, however.

I still need to order a replacement, as I had a busy week and haven’t got around to it yet. The replacement parts for the mudguard mount and handlebar bolt caps finally arrived though!

I started by removing the damaged and old parts from the mudguard mount.


I opened the packets and prepared the new parts

I fitted the replacement parts and tightened the bolts.

I then moved on to the handlebar mounting bolt caps. The original ones had been damaged after being removed and replaced multiple times.

I removed them a final time with the help of a small standard screwdriver.

The new caps compared with the old ones.

The new caps didn’t fit flush at first, as they needed more force when first fitted than I could manage with my bare hands.

A few taps with a wooden mallet later, they were quite snug in their new home.

Finally, I updated the task list for Sylvie.


I checked off the new tasks that were completed.

I realise later that I had forgotten to add the replacement footpeg cover, so I’ll be sure to add it over the next week!

I also go some work done on the compressor this week, so keep an eye out for a bonus post about that sometime soon!

Scarlet’s New Fuel Tap And Erica Gets Temporary Headlight Mounts

Scarlet’s old fuel tap had been leaking, so I wasn’t able to keep fuel in the tank. The replacement arrived last week, so this week I decided to fit it.

First I made sure the old tap was completely turned off and disconnected the fuel line from the carburetor.

I decided to run the hose directly into the nozzle from a fuel can to drain it.

The tank turned out to be basically empty anyway, so I removed it and put it on its side to remove the old tap.

The tap came off easily but left its inserts behind. I was able to coax them out with some needle-nose pliers.


The replacement tap. It’s not a genuine part but it’ll do for now.

New tap installed, Shiny!

The hose was a bit loose on the new tap, so I wrapped the outlet with teflon plumbers’ tape until I can get some thinner fuel line and popped the tank back on.

The mid fairings went on again next.


And finally the seat. Sylvie’s in the background and Erica’s in the foreground.

Speaking of Erica, the loose headlight had been bothering me.

I found some 13mm M6 bolts and matching washers in an assortment I picked up a while ago. They have 13mm hex heads and nuts but will do for now.

That’s all for this week. More on Erica’s headlight mounts once I get to looking at the wiring looms!


Sylvie Almost Loses A Bracket, Erica Gets A Panel Back And The Shed Clean-Up Continues

This week I’ve been continuing the clean-up of the bike shed while waiting for parts to arrive, as I made the mistake of using a router in it without considering dust extraction!

I’d noticed some rattling and scraping noises while riding Sylvie lately. On the way home this evening I figured out where it had been coming from!

The bracket on the right side of the mudguard had a loose bolt.

On further inspection, the whole bracket was dangling very loosely.

I tightened the front bolt enough to stop the scraping for now, as it appears the threads have stripped on the rear bolt and the rear thread on the bracket. I’ll order a replacement bracket and bolt now that I know what the problem is!

A lot of tyre and road dust had covered the rear of the mudguard, so I wiped it off with a soft rag.

I popped the right panel back on Erica to remind me what she’ll look like when she’s fully restored.

I had a lot of clutter on the bench to get through, even with the bench vice and cylinder head relocated. Next to be relocated was the bench drill, which was squeezed in the space left here!

I moved the stereo off the box, shifted the spare/seized CB250RS motor off the bench and reorganised a bit more.

I’ll be relocating the parts from Rosie to clear the other bench once this bench is properly cleared, so I’ll keep going with the reorganisation and hopefully have a much better laid-out shed next week!


Bonus Post – A Fuel Tap And Tank Swap For Erica

After setting up the mats, I took a couple of days break and decided I’d wheel Erica out into the sun to test the threshold ramp. It certainly made getting the bike out easier!

I decided to take a couple of full-view progress shots.

After trying unsuccessfully to kick-start Erica, I thought the leaking fuel tap in reserve position might be related, so I set about draining the black tank.

While draining the tank, I removed the seat in preparation for swapping the tank over.

I put the glovebox cover back on the rear cowl so I knew where it was and it wouldn’t get stepped on.

The fuel tank turned out to have about 3 litres of fuel in it.

I put the side panel on to p of the seat, as I didn’t want to risk stepping on it either!

THis side panel still has all 3 mounting pins intact and I’d like to keep them that way if possible.

I unlocked the tank cover and removed the cap to help get the last of the fuel out.

While I was at it, I removed the fuel tank locking strap, as its lock matches the rest on Erica.

The tank was placed over a suitable receptacleand turn upside-down to get the old fuel tap off.

I put the fuel line aside on top of the side panel for safe keeping.

I then examined the old fuel tap. The filter, o-ring and reserve pipe seem to be in reasonable condition so could be re-used.

THe tank was sloshed around until all the fuel that was coming out was out.

Tee frame was looking a bit bare, especially with only one tank mounting rubber.

I figured I may as well put the blue tank on Erica to get used to it. Although it has no visible dents, it’s sorely in need of repainting! Compared with the fuel cap from the black tank, this one has also lost a lot of its paint…

I unlocked the fuel cap cover and removed the fuel cap. The interior of the tank seemed to be in pretty good shape.

I removed the locking strap in preparation for fitting the original one again.

I compared the bases of the fuel caps from both tanks. The black one seems to be in better shape.


After a short break to photograph the blackboard lists for the Hondas (more on that in the last post) I dug out the aftermarket fuel tap. While there are a few differences from the leaking genuine one, it still has the right overall style and will do the job at least until the bike is running again!

I fitted the lid and locking cap from the black tank to keep the locks matching.

The thread for the tap was nice and clean already.

On went the aftermarket tap.

The fuel line was replaced next.

I pulled out the box of assorted CB250RS spares.

I found the grommets for the tank mounting pins.

I re-fitted the grommets to both sides

Popped the tank on.

I put the worn fuel cap on the black tank to go with the spares.

I put a small piece of rag inside the replacement fuel tank to make sure the fuel going in from the old tank was as clean as possible.

After pouring in the fuel from the drain pan, I found very little in the way of visible contaminants.

I replaced the rag and repeated the process for the fuel in the fuel can. This fuel had almost no visible contaminants.

I removed the mounting grommets from the black tank.

I sprayed them with Inox prior to removal.

To make sure they last as long as possible, I applied rubber grease to restore some of their elasticity

Once wiped off, I put them aside in the ziplock back I’d originally stored the grommets  from the blue tank in.

I fitted the leftover tank strap on the the black tank and put the tank away with the other larger spare CB250RS parts.

I noticed some discolouration of the front mudguard and rubbed my hand over it without thinking. Looking down, I saw shrivelled-up blue paint flecks on the ground and realised I’d just rubbed off some paint that brake fluid had dripped onto from the leaking master brake cylinder. I’ll have to rebuild or replace that master brake cylinder bore repainting!


After all that, I didn’t manage to get Erica to start after all. I’ll have to have a look into the electrical issues and maybe try another battery.

In the next post, I finally make some progress on the seized spare CB250RS motor at long last!