Build a Fun 4-wheel Buggy on Your Own!

Parts Procurement
04/20/2002 Updated


XLR250R 7-years left

Honda XLR250R, left outside and no longer be able to come back on the road.
The appearance looks extremely worned as it has been left outside for 7 years.


Frame with engine
The "frame with engine" has came to my home.
Now it's the time to start thinking what to do next.


What has been in there?
g shows inside of the froat chamber of carburetor right after it was opened.
I did not expect to see something inside like shown in the photo. Is it laver?...
Right after the overhauling, the engine revived successfully after 7 years of sleep.


Cool wheels!
These are aluminum die-casted front wheels for Honda Live Dio ZX, a 50cc scooter.
I purchased the wheels at a junk yard for 3,000Yen each.
I chose them because of the nice styling primarily, hoping to achieve a nice appearance of my buggy and looks tougher than conventional ones made with stamped steel.
These will be used for front wheels of my buggy.
I have to look for another 2 wheels for rear.


Nothing but free of charge Ready for use
I stopped at a racing kcart shop one day and asked to the master,
"Do you have any used seat for kart, hopefully at a reasonable price?"
He quickly said,
"You can get this one which is pretty worn out but with free of charge if you like."
... It looked berely usable even though it needed to be repaired slightly. Good thing was that it was offered for free of charge.
Then, I repaired the defective portions and partially reinforced with FRP at my home.
Now it is ready to work.


Defective carriper
A common problem regularly happens inside front brake calliper of XLR250R is that the piston sticks with the calliper housing, and it was really hard to attack.
Shop air blown into the carriper didn't work to get the pistons come out.
I put the brake hose again and filled the tank with the fluid, then operated the lever to push out the pistons.
I have had the same experience at another XLR sometime ago.
Another common problem I found on the brake system is that a crack happens on the piston like I experienced on another XLR in the past.
I guess these are common defects that happen on the brake systems of every XLR250R.
--> Due to dimensional reason at the frame structure, I decided not to use this caliper (04/20/2002).



These are rear shock absorbers for motorcycle that I purchased at a junk yard.
"We offer shocks for 1,000Yen for each if they no longer maintain the relevant performance."
I purchased two of them. These were originally for Kawasaki motorcycle.
A brake hose that I picked up from the ground was for free of charge.

Also purchased a brake roter which looked for me originally for a Honda 50cc scooter.
For my buggy, this rotor is supposed to be co-axially installed next to the driven sprocket on the drive shaft at the rear, so the brake system is assumed to control only the rear wheels.



Driven sprockets designed for Yamaha TZR50 (aftermarket parts) having 41 teeth for chain in size of 428.
Reason of the purchase of the 3 pieces of the same ones will be introduced later on as the project moves forward.
This particular sprocket was chosen because;
(1) The drive sprocket of XLR250R produced in 1987 was in the size of 428.
(2) Due to the use of 10-inch rear wheels for my buggy, I thought smaller final gear ratio would be preferable to achieve good drivability.
In thinking about combination of chain size 428 with smaller number of teeth, this was the only choice available.

Size of a drive chain purchased was 428 with length of 130mm.
These were on promotion at an Internet shop dealing with aftermarket parts for motorcycles.
Price was only 1,000yen for each.
These are non-sealed type that is applicable up to 125cc but I expect it works.
The chain can be cut into length later.



A meter assembly for Honda GB250 Clubman.
I had searched for this particular type because XLR250 originally didn't have its tacho meter, and I knew that the meter of GB250 certainly fits XLR250 electrically upon slight modification on the wiring system.
Tacho meter is a must item to enjoy driving of non road-going vehicles.



A silencer of Kawasaki ZXR250 that I purchased through an Internet auction. It is to be installed as well...



Steel pipes are ready. Work bench may have to be built firstly to get my work environment...



While putting on hold what I really want to build (the object was a buggy, not a work bench!), Kobayashi-san, a friend of mine living in Hiroshima prefecture, sent me a large box in that he packed number of treasures such as universal joints & shafts, brake calipers, new shock absorbers, and bearings.
The weight of box was as heavy as 30kg. I received a message from him saying "I no longer need these all and I would like to offer them for your own project"
He said those parts had been stored somewhere in his company, and it came in front of him unexpectedly when his office got relocated to another place.
He also said he did not need any of these any longer because he is getting out of interest in this type of activity he had got used to. Anyway, thanks for him!



I have ordered assort of bearings and rod ends, and they were delivered. I ordered them from a bearing shop that I found through the Internet.
I have not expected that I could purchase this kind of products through the Internet although I was doing some web searching expecting to find a shop like this.



Aftermarket new shocks for Honda Monkey at a less expensive price I got through Internet auction. The pitch of 280mm, hole to hole, fits the front suspension layout of my buggy.


Trail tires of 4.00-10. Purchased through Internet shopping site operated by a motorcycle parts shop.
I was thinking of motocross tires with more height of block patterns, however due to the size only available in the market (2.50-10) that looked too slim for the wheels I have already procured, I gave up hope using them and decided to go with the ones shown in the photo.
2 of them (left ones) are made by Bridgestone and the other 2 (right ones) are by Dunlop.
I also purchased the tubes as they were required.



A fuel tank, whatever the type is, will be necessary for run.
I looked for a good one through an Internet auction. I found a set of a fuel tank, a base tray, tightening belts, and an oil tank for Suzuki Sepia ZZ, 50cc scooter, for 500 yen.
The black one is fuel tank with the capacity of 5L. Oil tank might be used as a reserver.



A brake caliper that looks originally for Honda GB250. I found it in a box of parts brought by a friend of mine.
I thought the pads for XLR could be used in combination with the caliper, but it could not. Base plate of the pad must be cut by 2mm at both ends to get it installed.
I will re-use the all pistons and the seals as they looked still alive. Material of the pistons is steel, instead of plastic used for XLR ones. No sticking with caliper housing was observed so that I could easily remove the pistons simply by air blowing.


... To be continued.

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