2024 — Yamaha Zeal 250 / 249cc
Yamaha Zeal 250
Café Racer / Bobber Hybrid
A dual cradle Yamaha Zeal 250 transformed into a bobber-café hybrid — stripped back, functionally refined, and visually deliberate. Every modification serves both form and mechanical intent. The dual cradle frame's natural geometry made it an ideal base for a low, purposeful silhouette.
Status
fabrication
Category
café-racer
Published
May 22, 2026
Engine
249cc
Design Philosophy
The Zeal's dual cradle frame naturally lends itself to a clean bottom line. The goal was to strip unnecessary mass while keeping the mechanical character visible — letting the engine breathe and the silhouette speak. No filler panels, no fluff. If it doesn't serve the machine or the eye, it doesn't stay.
Build Timeline
Jan 2024
Acquisition
Located a clean 1994 Zeal 250 with original engine. Low mileage, some surface rust on the frame — workable.
Feb 2024
Full Strip
Complete teardown. Removed all original bodywork, wiring harness cleaned up, carb pulled for rebuild.
Mar 2024
Frame Prep
Subframe loop cut and rewelded at a lower angle. Frame powder coated matte black.
Apr 2024
Tank Fitment
Sourced a low-profile generic scrambler tank. Custom bracket fabricated for clean fit on the Zeal's spine.
May 2024
Electrical Rebuild
Full rewire using Motogadget m-unit. Eliminated unnecessary circuits. Clean loom, minimal connectors.
Problems & Fixes
Problem
Original carburetor had a slow fuel delivery issue causing lean stutter at mid-throttle.
Fix
Full carb rebuild with new jets, needle clip raised one position. Idle mixture adjusted via vacuum gauge.
Problem
Subframe weld cracked on first test ride — original weld quality was insufficient for the new angle.
Fix
Re-welded with TIG by a professional fabricator. Added small gusset plate at stress point.
Problem
Tank bracket vibrated against the frame spine above 6000 rpm.
Fix
Added rubber isolation bushings between bracket and tank mounts. Eliminated resonance completely.
Parts Used
Motogadget m-unit Basic
Motogadget
Central electrical hub, replaces fuse box and relay block
LSL Superbike Handlebars
LSL
22.2mm, 650mm width, matte black
Renthal Grips
Renthal
Dual compound, black
Biltwell Moto Bar End Mirrors
Biltwell
Anodized black, minimal profile
Daytona Velona60 Speedometer
Daytona
60mm, white face, black housing
Hagon Rear Shocks
Hagon
280mm, spring rate matched to rider weight
LED Turn Signals
Generic
Bullet-style, 10mm stem
Fabrication Notes
The subframe loop was the most critical fabrication point. The original Zeal subframe rises too high — cutting it down and rewelding at 15° lower created the flat, purposeful tail line. The bracket for the tank required three iterations before achieving zero vibration. All welds were MIG except the structural subframe which was TIG-finished.
Future Plans
Seat pan fabrication is next — currently mocking in foam. Target is a flat, narrow profile with a tuck-and-roll leather finish. After that: custom exhaust wrap, front fender delete, and final paint. Considering a raw brushed metal finish on the tank with minimal decals.