RD250 Cafe – Handlebars

This one should be short and sweet. We’re removing the handlebars and controls today. The handlebars are held in place by two large bolts that pass through rubber shock absorbers. By removing two cotter pins, two nuts, and the front brake line, the handlebars should pull free. First, remove the two cotter pins and nuts as

Pen Turning Made Easy

After sitting in front of a computer for 8 hours a day, there’s something extremely cathartic about finishing a hands-on project in the shop. The “finishing” parts are usually few and far between with as many “in progress”  projects I have on my roster. Enter the artform of pen turning. In the span of half

RD250 Cafe – Back End

It’s been awhile since I’ve sat down to type up the progress on the bike. I’ve gotten so far ahead of myself that I’m scared without proper documentation I won’t be able to get this thing back together! So taking a break from the garage to write up some past work.

In this entry, I’ll be looking at removing the back-end, including the lights, rear fender, and rear tire. Last time we finished up with removing the main harness and battery box.

RD250 Cafe – Main Harness Removal

DISCLAIMER: This is going to be a lot of detailed tracing of the main harness. It’s probably interesting and very helpful to someone that needs to do the same or has a question about the process, but probably pretty monotonous for casual reading.

Last time I detailed (well, kind of) the removal of all the junctions that meet behind the headlamp. Actually, most of the details were left out, but I provided a diagram showing the junctions and each of the 6 places they could go (plus the Left and Right front turn signals). As a recap, here are the main bundles that come into the junction behind the headlamp: