HONDA TL 250 Bials 1975 Project

Part 6: Fine Tuning 2008

I bought the project around Easter 2005 and started competing in earliy 2006 at the French AFATA Trial in Luxeuil. There is always some things to improve or restore at a classic trials bike and you have to source parts. I'm now quite statisfied, as I reached 3rd place at the AFATA Trial La Roche en Brenil 2008, in front of very light and nice TLR 200 and 250...

Here some modifications I made 2007/2008 since Part 5 in 2006:

here the longer clutch lever for 1 finger clutch, new needle barings as I lost the rubber cover for clutch adjusting, I now fixed it with a small plate	Hebo foot pegs, had to "flex" about 1mm, to fit into the peg holders, good stand for boots and better control, kicker still passes lever was drilled and chromed by former owner
here my 2007 version for a lighter saddle unit, as the original iron saddle is 1 kg !!! Kicker from ebay (rare and expensive)	here the 2008 alu version, looks nicer, below is a tool box (a cut alu bottle)
Top view of my new saddle unit I also fitted a Domino short stroke throttle unit, for instant power at brutal climbs	I frist made a model with paper, then cut an alu sheet, bended it over the frame, drilled the holes for the fixing screws the Sammy Miller 125 swan neck neds a fixing at the frame and a silicon tube for sealing
I cut out of a black camping mat 2 pads, ground them with a band machine,  makes round edges,	top view, the intake of the airbox has to be cut, otherwise gets asthmatic...
the lower pad needs some cuts to fit the tank and mudguard, fixed them with double carpet tape	added some home made stickers and gained 1 kg !
I swapped the Sammy Miller TL 125 silencer used in 2007 against a DG bought in ebay for a 500cc crosser, shortened it, revs easier now My dream (next project) would be a TLR 200 stile WES alu under the airbox....	the falcon 40cm shocks are really great, lift ground clearance and make the bike handier the original heavy silencer won't fit anymore (standard is 36 or 38cm?)
I bought a new coil / condensor to be an the save side, (advancer also new) clutch cable needs careful routing	I like this view of the big cylinder... Engine weight is 40 kg, whole bike 101kg, 45 front / 56 back click here for a 1MB clip and listen
Sammy Miller TL 125 front mudguard stay (needs an additional homemade alu plate) Handle is 2.5cm higher Renthal 5.5 inches (13.75cm) instead of normal 4.5 (11.25cm), I also drilled out inside the fork oil pass holes, as the fork remained stiff even with 2.5 fluid	fitted a Beta alu gear lever, needs some scratching to make it smaller
Street legal equipement, got now a Swiss road licence with an Oldtimer stamp ! I need it for Italy, as it is always a roulette at the customs...(yes, we Swiss are not EU members...) big work, till all the electric works and the cables are properly routed... here with nice alu mudguards, looks more classic	for memory the 2005 bike as I bought it looks not so bad, but it needs parts and time till everything works fine...
Clubtrial Eiken, Nov 2008 Renthal 5.5 inches (13.75cm) handlebar instead of todays 4.5 (11.25cm)	engine was running nicely, but no chain, could not try the bike... as soon as you open something, inside needs parts to be exchanged... this is called restauration...
wheely in Nans 2007, where I won the Twinshocks National Class	jipee, Moudon 2008 the joy of a good running bike

Here 2 morer TL 250 specials in Switzerland plus I know from 2 parts bike in boxes at a Swiss Collector

a TL 250 with cut bottom frames and fitted alu slide plate	nice chrome exhaust system
this TL 250 was converted in the direction of the white works TL300 cut frame bottom and rear	nice white / red works colours
here a real US works TL 300 with square front tube and nice tank unit big exhaust box, about 10kg lighter than a standard TL 250 I guess compare the details with above TL 250...	the carved out tank is really unique for this model
I could test ride the little beauty 2007 in Soultz, felt like a 125cc against my 101kg TL 250

My conclusion: It took time and work to built the bike. It was a challange to source the parts, but got many in ebay and found some internet adresses. The bike is 101 kg heavy and I'm competing at AFATA French trials against the modern 1983 TLR 200-250 etc., which is a disadvantage. The most competitive Honda is for sure a TLR 250 1983. I think, against real 1975 bikes, it is very competitive with my modifications. Pitty, Honda could not sell the 4000 units in USA and did not produce Sammy Millers lighter and slimmer TL300 later on.

I have fun riding a rare and special bike (in Europe), hearing the great sound of the 4 stroker and sometimes I manage to beat the more modern bikes. This is for me the joy: Riding a nice trial, meet other enthousiasts, see different oldtimer, feeling some years back in the past. I know each screw and part and I'm proud everything works fine.

Here some TL 250 running today

Bruce Watts TL 250	Bruce shipped his TL 250 from South Africa to Europe and competed in Zirndorf 2007 and Isle of Man Classic Trials 2007

some useful links for parts:

www.bjracing.com US, great shop

www.davidsilverspares.co.uk has a lot of new parts (advancer, etc)

www.cmsnl.com Dutch dealer of old stock parts (cam chain, bolts, coil, etc)

www.econohonda.co.nz New Zealand (service manual)

www.talon-eng.co.uk (rear sproket 57T) great service

www.tytrials.com UK shop, brake pads, etc

www.sammymiller.co.uk TL 125 parts like mudguard holder, swan neck exhaust tube,

ebay.com: new gasket and sealing sets, used TL 250 parts

Orlando Calonder: THE Bultaco source, but also has Mudguards, spokes

Moto Taiana, Zürich: Great mechanics, newly sealed the engine and fitted the valves, Trial riders and Oldtimer knowledge

If you need some advice or also own a TL250  Honda, please contact me

patrick@twnclub.ch

Patrick, December 2008