tag:blogger.com,1999:blog-35699628674467808652023-11-15T05:46:08.285-08:00Yamaha XS 250 Bobber ProjectSimon_Dhttp://www.blogger.com/profile/04721848826226894712noreply@blogger.comBlogger8125tag:blogger.com,1999:blog-3569962867446780865.post-20252298095492200202012-01-29T08:13:00.000-08:002012-01-29T08:17:29.937-08:00ProgressionsThe unit is finally looking more like a workshop rather than an empty space with an open plan toilet. There has been a lot to do to get it this far. As well as building a work bench i've also upgraded the security, built a stand for the frame jig and also the frame jig its self. Now all i have to do is build the motorbike! (the camera is on top of the stand and jig so you can't see them). <br />
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<div class="separator" style="clear: both; text-align: center;"><a href="http://3.bp.blogspot.com/-AOSv4nahjKE/TyVoEHsF4xI/AAAAAAAAAD8/5EPrPW4V8RE/s1600/Capture.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="360" src="http://3.bp.blogspot.com/-AOSv4nahjKE/TyVoEHsF4xI/AAAAAAAAAD8/5EPrPW4V8RE/s640/Capture.JPG" width="640" /></a></div><br />
I am using the 3D modelling software Solidworks to model up all my designs for the workshop. I use the models to give me dimensional details of the design. Below is a picture of the frame in the jig with the engine mounted. <br />
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<div class="separator" style="clear: both; text-align: center;"><a href="http://2.bp.blogspot.com/-r6HI8x1-HXc/TyVrJ68AoVI/AAAAAAAAAEE/5Pbtzx0tYr0/s1600/Capture2.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="534" src="http://2.bp.blogspot.com/-r6HI8x1-HXc/TyVrJ68AoVI/AAAAAAAAAEE/5Pbtzx0tYr0/s640/Capture2.JPG" width="640" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: left;">and the real thing ...</div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="http://2.bp.blogspot.com/-TqbrZDIGIro/TyVrau_QJfI/AAAAAAAAAEM/jpi0HpT4Fgo/s1600/2012-01-27+18.39.22.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="454" src="http://2.bp.blogspot.com/-TqbrZDIGIro/TyVrau_QJfI/AAAAAAAAAEM/jpi0HpT4Fgo/s640/2012-01-27+18.39.22.jpg" width="640" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: center;"><a href="http://3.bp.blogspot.com/-HpMlX9EwiIk/TyVrmv71ckI/AAAAAAAAAEU/vLsNpcZ6Thk/s1600/2012-01-28+17.32.04.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="http://3.bp.blogspot.com/-HpMlX9EwiIk/TyVrmv71ckI/AAAAAAAAAEU/vLsNpcZ6Thk/s640/2012-01-28+17.32.04.jpg" width="640" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: left;">The frame is not far off being finished now. A few more supports here and there and it will be ready for engine prep :D </div><div class="separator" style="clear: both; text-align: center;"><br />
</div>Simon_Dhttp://www.blogger.com/profile/04721848826226894712noreply@blogger.com0tag:blogger.com,1999:blog-3569962867446780865.post-26582919622417596962011-12-07T12:29:00.000-08:002011-12-07T12:33:45.420-08:00New WorkshopThe eagle eyed readers amongst you will have noticed that my last post was back in August! this is for 2 reasons. Firstly a broken wrist ...<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="http://4.bp.blogspot.com/-Q9o-6qqR7iI/Tt_JjVmNJ3I/AAAAAAAAADg/Yr-2XIvtZQo/s1600/2011-09-27+11.58.19.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://4.bp.blogspot.com/-Q9o-6qqR7iI/Tt_JjVmNJ3I/AAAAAAAAADg/Yr-2XIvtZQo/s320/2011-09-27+11.58.19.jpg" width="240" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: left;">and secondly i've been preoccupied trying to find a job of some description. Lucky the nice people at Nissan invited me into there plant to work as a graduate engineer. The move to Nissan meant that i needed to find a new work shop for the bobber. A bit of internet surfing and i had found myself a second home.</div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="http://4.bp.blogspot.com/-YnRnGOw8In0/Tt_LfGEEteI/AAAAAAAAADo/dg7XEUjZmxc/s1600/DSCF7701.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="http://4.bp.blogspot.com/-YnRnGOw8In0/Tt_LfGEEteI/AAAAAAAAADo/dg7XEUjZmxc/s640/DSCF7701.JPG" width="640" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: left;">its got a toilet and everything! As you can see by the material sitting on the floor there's plenty to build to get it looking like a proper workshop which i'll be doing over the next few weeks. WATCH THIS SPACE. </div><div class="separator" style="clear: both; text-align: left;"><br />
</div>Simon_Dhttp://www.blogger.com/profile/04721848826226894712noreply@blogger.com0tag:blogger.com,1999:blog-3569962867446780865.post-12610155442369041762011-08-24T11:22:00.000-07:002011-08-24T11:25:45.472-07:00Frame Design<div dir="ltr" style="text-align: left;" trbidi="on">Finally got around to posting a new blog entry. I've been busy trying to arrive at a final design for the frame. I've run into problems trying to make the frame look how I want but also keeping it strong enough to not collapse when am giving it full beans. The drawing below is what i have for now but i wouldn't be surprised if it needs some more small modifications :/<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="http://3.bp.blogspot.com/-9LnP9Xgrsyc/TlU9d8mfEWI/AAAAAAAAAC0/u-fF2mIam4c/s1600/img001.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="http://3.bp.blogspot.com/-9LnP9Xgrsyc/TlU9d8mfEWI/AAAAAAAAAC0/u-fF2mIam4c/s640/img001.jpg" width="544" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: left;">This is the working drawing for the jig i have designed through solidworks to mount the frame. Hopefully this jig will help maintain a high level of accuracy. I'm having to use a professional metal fabricator to machine some of the bits on the jig for me. Hopefully the next entry will have a picture of the real thing! </div><div class="separator" style="clear: both; text-align: left;"><br />
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</div><div class="separator" style="clear: both; text-align: center;"><a href="http://1.bp.blogspot.com/-wdDi5ggNizI/TlU-HEDg6kI/AAAAAAAAAC4/7qtKIzuvJ64/s1600/img002.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="http://1.bp.blogspot.com/-wdDi5ggNizI/TlU-HEDg6kI/AAAAAAAAAC4/7qtKIzuvJ64/s640/img002.jpg" width="444" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
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</div>Simon_Dhttp://www.blogger.com/profile/04721848826226894712noreply@blogger.com2tag:blogger.com,1999:blog-3569962867446780865.post-66494716782052673212011-07-24T16:30:00.000-07:002011-07-24T16:34:11.057-07:00Concept Bike<div dir="ltr" style="text-align: left;" trbidi="on">The engine is nearly rebuilt now so i am going to need a frame to mount it in before i can get it fired up. I've been reading Motorcycle Dynamics by Vittore Cossalter to try and get my head around motorcycle dynamics but it turns out its all hideously complicated. I took a few recommended dimensions out of the book and copied the original frame in a few places and this is what i got so far: <br />
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<div class="separator" style="clear: both; text-align: center;"><a href="http://1.bp.blogspot.com/-NB4Ls92P4Mw/TiykYYBGK6I/AAAAAAAAACE/wyfI4ppD6ek/s1600/Solidworks.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="350" src="http://1.bp.blogspot.com/-NB4Ls92P4Mw/TiykYYBGK6I/AAAAAAAAACE/wyfI4ppD6ek/s640/Solidworks.JPG" width="640" /></a></div><br />
brooooooooooom broom brom broom broom broooooom broom broom <br />
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</div>Simon_Dhttp://www.blogger.com/profile/04721848826226894712noreply@blogger.com0tag:blogger.com,1999:blog-3569962867446780865.post-1335328385509922562011-07-22T05:27:00.000-07:002011-07-22T05:27:04.757-07:00Re-assembling Fun<div dir="ltr" style="text-align: left;" trbidi="on"><div class="separator" style="clear: both; text-align: center;"></div><div style="text-align: left;">It turns out that rebuilding engines at actually very expensive :/ new crank bearing shells, big end bearing shells, full gasket set, gasket cement, torque wrench, oil seals, piston circlips, oil filter and a few other bits and bobs all add up. I've been using padgetts motorcycles (<a href="http://www.padgettsmotorcycles.com/">http://www.padgettsmotorcycles.com/</a>) as a supplier who have always had the parts in and fast delivery so they get two thumbs up from me.</div><div style="text-align: left;"><br />
</div><div style="text-align: left;">I've been storing everything that has come off the engine in Chinese take-away boxes. I thought i would share this with you because it works so well. Cheap to buy, they keep everything clean and contained, they are compact, easy to label and they can be re-used.</div><br />
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</div><div class="separator" style="clear: both; text-align: center;"><a href="http://1.bp.blogspot.com/-ue1vWdu4JHI/TilP_CoqmsI/AAAAAAAAAB4/F39-Z4OY_c4/s1600/2011-07-19+20.56.48.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://1.bp.blogspot.com/-ue1vWdu4JHI/TilP_CoqmsI/AAAAAAAAAB4/F39-Z4OY_c4/s320/2011-07-19+20.56.48.jpg" width="240" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: left;">With all my spares to hand it wasn't long before it was looking like an engine again.</div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="http://3.bp.blogspot.com/-B0kuHbEta18/TilrPHaGpiI/AAAAAAAAAB8/IPUEn5IHyfU/s1600/2011-07-19+20.57.07.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="http://3.bp.blogspot.com/-B0kuHbEta18/TilrPHaGpiI/AAAAAAAAAB8/IPUEn5IHyfU/s640/2011-07-19+20.57.07.jpg" width="480" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: left;">After re-installing the pistons to the connecting rods and getting all the piston circlips in i finished up last night trying to get the pistons into the cylinder block which i didn't have enough hands for so i called it night.</div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="http://4.bp.blogspot.com/-uqjcnORCnsg/TilsII-ERJI/AAAAAAAAACA/0Q8-KV_u9rg/s1600/2011-07-19+21.43.33.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://4.bp.blogspot.com/-uqjcnORCnsg/TilsII-ERJI/AAAAAAAAACA/0Q8-KV_u9rg/s320/2011-07-19+21.43.33.jpg" width="240" /></a></div><div class="separator" style="clear: both; text-align: left;"><br />
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</div>Simon_Dhttp://www.blogger.com/profile/04721848826226894712noreply@blogger.com0tag:blogger.com,1999:blog-3569962867446780865.post-22279942804573684442011-07-17T16:30:00.000-07:002011-07-17T16:30:00.897-07:00Cleaning, cleaning, cleaningWith the engine now in pieces i broke out the iron wool and got scrubbing. A few days later and every part is looking factory fresh again. Here's just a few bits and pieces...<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="http://2.bp.blogspot.com/-1up_Nx7ew_Y/TiNvkAFsC1I/AAAAAAAAAB0/jgZDqO7s5NY/s1600/2011-07-13+18.04.35.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://2.bp.blogspot.com/-1up_Nx7ew_Y/TiNvkAFsC1I/AAAAAAAAAB0/jgZDqO7s5NY/s400/2011-07-13+18.04.35.jpg" width="400" /></a></div>Simon_Dhttp://www.blogger.com/profile/04721848826226894712noreply@blogger.com0tag:blogger.com,1999:blog-3569962867446780865.post-78297655177574191372011-07-13T08:19:00.000-07:002011-07-13T10:00:55.186-07:00Strip Down<div style="text-align: center;"><div style="text-align: left;">With bible in hand...</div></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="http://3.bp.blogspot.com/-Hl82M9kAlXo/Th2yvyAyk9I/AAAAAAAAABc/eA4RPRBJvaQ/s1600/RGBhr_0378.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://3.bp.blogspot.com/-Hl82M9kAlXo/Th2yvyAyk9I/AAAAAAAAABc/eA4RPRBJvaQ/s320/RGBhr_0378.jpg" width="246" /></a></div><br />
I set about taking the engine to pieces. First I removed the engine from the frame<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="http://3.bp.blogspot.com/-duD-75Q33FM/Th2z43PCQzI/AAAAAAAAABg/X7O82MQrvPM/s1600/2011-06-15+16.05.59.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="http://3.bp.blogspot.com/-duD-75Q33FM/Th2z43PCQzI/AAAAAAAAABg/X7O82MQrvPM/s320/2011-06-15+16.05.59.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: left;">and then after knocking up an engine stand.....</div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="http://2.bp.blogspot.com/-UD2gS5Lu8lY/Th20r44Nq7I/AAAAAAAAABk/sFUuukUe004/s1600/2011-06-20+17.18.59.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="http://2.bp.blogspot.com/-UD2gS5Lu8lY/Th20r44Nq7I/AAAAAAAAABk/sFUuukUe004/s320/2011-06-20+17.18.59.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: left;"><span class="Apple-style-span" style="font-family: Arial, Helvetica, sans-serif;"> </span></div><div class="separator" style="clear: both; text-align: left;"><span class="Apple-style-span" style="font-family: inherit;">I could start unbolting stuff!</span></div><div class="separator" style="clear: both; text-align: left;"><span class="Apple-style-span" style="font-family: inherit;"><br />
</span></div><div class="separator" style="clear: both; text-align: left;"><span class="Apple-style-span" style="font-family: inherit;">The first problem i ran into came a</span><span class="Apple-style-span" style="font-family: inherit;"><span class="Apple-style-span" style="line-height: 18px;">fter trying to remove a tight cylinder head nut and ending up rounding it off. The position of the nut couldn't have been any worse.</span> </span></div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="http://1.bp.blogspot.com/-9Yn-FYU8_Pg/Th246s3VP-I/AAAAAAAAABw/EGvkZHDL4Lc/s1600/2011-06-20+17.30.34.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="http://1.bp.blogspot.com/-9Yn-FYU8_Pg/Th246s3VP-I/AAAAAAAAABw/EGvkZHDL4Lc/s640/2011-06-20+17.30.34.jpg" width="640" /></a></div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: left;">The indent on top is were i tried to make a groove on top using a chisel then use a flat head screw driver to get it off which didn't work then the small hole you can see is the remains of my attempt to weld an Allen key to the top then use that as leverage but that didn't work either. </div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: left;">If anyone out there<span class="Apple-style-span" style="line-height: 18px;"><span class="Apple-style-span" style="font-family: inherit;"><span class="Apple-style-span" style="font-size: x-small;"> </span>needs advise on how to remove a rounded off nut or bolt here's mine...</span></span></div><div class="separator" style="clear: both; text-align: center;"><span class="Apple-style-span" style="font-family: Verdana, Geneva, sans-serif; font-size: x-small;"><span class="Apple-style-span" style="line-height: 18px;"><br />
</span></span></div><div class="separator" style="clear: both; font-family: Verdana, Geneva, sans-serif; font-size: 13px; line-height: 18px; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.youtube.com/embed/wfUGNEaQ2FI?feature=player_embedded' frameborder='0'></iframe></div><div class="separator" style="clear: both; font-family: Verdana, Geneva, sans-serif; font-size: 13px; line-height: 18px; text-align: left;"><br />
</div><div class="separator" style="clear: both; font-family: Verdana, Geneva, sans-serif; font-size: 13px; line-height: 18px; text-align: left;">This may look like another cheesy American gimic but it got the nut off with ease and i couldn't be happier with my Grip Tites.</div><div class="separator" style="clear: both; font-family: Verdana, Geneva, sans-serif; font-size: 13px; line-height: 18px; text-align: left;"><br />
</div><div class="separator" style="clear: both; font-family: Verdana, Geneva, sans-serif; font-size: 13px; line-height: 18px; text-align: left;">With the Cylinder head off the rest off the dismantling was all straight forward. Internally everything looked in good working order apart from one half of the crank casing which had a small crack and needed to be professionally repaired.</div><div class="separator" style="clear: both; font-family: Verdana, Geneva, sans-serif; font-size: 13px; line-height: 18px; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="http://4.bp.blogspot.com/-rclTaziDdf8/Th21QhKecGI/AAAAAAAAABo/pPVOL-9dQRE/s1600/2011-07-01+15.45.12.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="http://4.bp.blogspot.com/-rclTaziDdf8/Th21QhKecGI/AAAAAAAAABo/pPVOL-9dQRE/s320/2011-07-01+15.45.12.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="http://4.bp.blogspot.com/-LHwHByX4R6I/Th21qVimZfI/AAAAAAAAABs/fDtX3qWT0MM/s1600/2011-07-01+17.22.12.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="http://4.bp.blogspot.com/-LHwHByX4R6I/Th21qVimZfI/AAAAAAAAABs/fDtX3qWT0MM/s320/2011-07-01+17.22.12.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
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</div>Simon_Dhttp://www.blogger.com/profile/04721848826226894712noreply@blogger.com0tag:blogger.com,1999:blog-3569962867446780865.post-51656014150955132242011-07-13T07:38:00.000-07:002011-07-13T09:43:48.933-07:00In the Beginning...My name is Simon and I like Motorbikes.<br />
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Building my own motorbike has been at the top of my list of things to do since I can remember and now with my Motorsports Engineering degree behind me I think its about time I started. This project has been inspired by the stunning bikes created at Falcon Motorcycles:<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="http://3.bp.blogspot.com/-EzSI_QqUWac/Th2nn8SSY1I/AAAAAAAAABY/CHbgPEQPhH0/s1600/Falcon.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="280" src="http://3.bp.blogspot.com/-EzSI_QqUWac/Th2nn8SSY1I/AAAAAAAAABY/CHbgPEQPhH0/s640/Falcon.JPG" width="640" /></a></div><br />
So where to start? .... In Ebay we trust.<br />
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Initially I wanted to use an old British motor such as a Triumph or BSA but after seeing rusty old engines which were in pieces go for quadruple figures (!) I had a re-think and decided Japanese was the way to go as they are cheaper to buy easier to find spares for. After a bit of searching a came across this beauty.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="http://3.bp.blogspot.com/-qtDnSs_R7ok/Th2kD-rzdlI/AAAAAAAAABQ/0yREwCdh2Ao/s1600/Ebay.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="241" src="http://3.bp.blogspot.com/-qtDnSs_R7ok/Th2kD-rzdlI/AAAAAAAAABQ/0yREwCdh2Ao/s320/Ebay.JPG" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: left;">A 1977 Yamaha XS 250. To the untrained and trained eye is an absolute state. Needless to say it is non-running, needs a lot of TLC but it is just want I am looking for. </div>Simon_Dhttp://www.blogger.com/profile/04721848826226894712noreply@blogger.com0