78' KL250

I've been working on a 15k mile 78' KL 250 I picked up for the boy to learn on. My biggest hurdle was swingarm bushings and the rotten exhaust. I've already made swingarm bushings from Delrin and now I'm almost done building an exhaust system. I used the stock headpipe, parts of the number 2 and 3 headpipes from the old 82' CB 900F exhaust and the old right side muffler from the 84' Honda Sabre 700. I still have to make a muffler mounting bracket for it and fix/reinforce the broken off coil mount.Then I can get on with pulling the motor and sandblast the frame, swingarm and related parts. Rick Brett even made me a new set of VIN stickers for it.

Great work as always Kelly 

I got the muffler mount made today.

We've got the frame sandblasted and ready for paint. Yesterday I reinforced the lower rock guard mount and today I made the rest of the rock guard to cover the bottom of the frame. I have to put the motor in one more time to make sure the drain plug access hole is in the right spot. I'm now waiting for a good day to get the painting done.

Today we got the frame painted. We painted it in the new shed on the back of the shop out of the direct sunlight. I was able to see way better and the paint wasn't turning to dust before it hits a nearby frame tube. Once done we carried it back in and hung it up. Tomorrow I'll get it raised up high to cure. In a couple of weeks I'll pull it down to mask off the areas that will be sprayed with bedliner.

We've got the motor in the frame and the suspension installed. I have to put on the new VIN sticker from Rick Brett and I was wondering if anyone has any tips for installing it?

Nice project Kelly i really like these old enduro bikes the yamaha xt500 with double shock and the xl500 and many more. When i was young and stupid
i borrowed a suzuki DR600 and did a wheelie and landed on my back .Then i had the embarresing job picking up broken pieces from the street while some people  watching
Now im 55 and still stupid ,but not That  stupid

We've made some more progress on it. We got it mostly back together now, I have to get the headlight bucket back on to get the wiring done. The new handlebars came and I got all of the wire routing brackets blasted and painted so we can finish up the front half of the bike.

Well I finally got back to this bike. For the last couple of days I've been scratching and scraping with a tool made from 2mm spring steel rod trying to remove the flaking and chipping fibreglass resin that the PO tried to line the tank with. The fuel petcock is plugged with resin and is trash. The vent passages in the gas cap were completely plugged too but I was able to get it apart and cleaned out the vent passages.
Previously I had soaked and rinsed the tank out with acetone with no sign of leaks. Now it's filled to the brim with EvapoRust for the next few days. This is the last big task on the bike, just some odds and ends to take care of and it will be time to try starting it up.