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Benelli 250R

Fitting the quirky two-stroke, air-cooled single from the first-gen Honda ATC250R into a Benelli 2C frame.
NOTE: I am assembling this as a non-running static display only.

Drive chain fitted
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  • Benelli 250R

Drive chain fitted

April 17, 2025April 17, 2025

I bought a $35 RK non-o-ring chain to verify I had the engine aligned properly. The chain run is spot-on. The only minor issue is that the chain rivets barely graze the … Drive chain fittedRead more

Fitting the engine
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  • Benelli 250R

Fitting the engine

April 14, 2025April 14, 2025

I now have the ATC250R engine solidly bolted into the Benelli 2C frame. I had to do a bit of additional grinding on the frame, but there is just enough room for … Fitting the engineRead more

Cuts to the Benelli frame
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  • Benelli 250R

Cuts to the Benelli frame

April 4, 2025April 4, 2025

After shifting the ATC250R cases around in the Benelli frame a bunch, I came to the conclusion that getting the engine to sit where I wanted would require some cutting. I got … Cuts to the Benelli frameRead more

…And we have a roller.
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  • Benelli 250R

…And we have a roller.

March 21, 2025March 25, 2025

No shocks, but I put a strut in that tells me a 12″ shock would be just about right. I sat on the frame rails and did some S-turns down my slightly … …And we have a roller.Read more

Into the frame jig you go!
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Into the frame jig you go!

March 18, 2025March 25, 2025

I intended to align the Yamaha rear wheel in the Benelli frame as well as I could without resorting to my frame jig, which was in a storage unit across town. After … Into the frame jig you go!Read more

Fitting the M-bar
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  • Benelli 250R

Fitting the M-bar

March 16, 2025March 25, 2025

I bought a knockoff Hyde “M-bar” bend handlebar about six years go, but could never use it because the center section is too narrow to fit the handlebar clamps of nearly any … Fitting the M-barRead more

Front brake stay
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Front brake stay

March 12, 2025March 18, 2025

I made a brake anchor the Benelli’s front wheel using an old alloy rear brake stay I’ve had for a while. (I seem to recall it being a Bultaco part, but its … Front brake stayRead more

Fork gaiter modification
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  • Benelli 250R

Fork gaiter modification

March 5, 2025March 7, 2025

To help impart a more vintage look to the front end of the Benelli, I popped for a $30 set of universal fork gaiters. I chose a set to match the diameters … Fork gaiter modificationRead more

Yamaha sprocket carrier modification
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  • Benelli 250R

Yamaha sprocket carrier modification

March 4, 2025March 4, 2025

My initial fitment of the Yamaha YM2C rear wheel in the Benelli swingarm showed me that some surgery was required. Specifically, I needed to employ the same technique I used on the … Yamaha sprocket carrier modificationRead more

Swingarm installation
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  • Benelli 250R

Swingarm installation

February 25, 2025February 25, 2025

Talk about mis-remembering. I thought I had modified the Benelli frame to fit the current swingarm pivot. Nope. I forget where it came from, but it’s exactly the same length and diameter … Swingarm installationRead more

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