2002 Honda CR250 Build

Almost 4 months ago I traded a guy for a perfectly running and cosmetically decent bike I had for this decent for its age 2002 CR250. While driving on my way, An hour before arriving, he called saying he couldn’t get it to start. Determined mindset me goes full speed with the plan of trading. He tried everything in the world, (I was going to let him eventually give up so I could possibly make the deal a little better since he couldn’t get it running, The bike had been sitting for years untouched or ridden with gas sitting in the carb the whole time so that’s a dead giveaway it’s a fuel issue if you know you have spark). Long story short he finally figured out it wasn’t getting fuel, got the float unstuck, got it running and I accepted his fair trade. Took the bike home and immediately tore it apart to find out what I had and to do a ground up build!


Wish I would have gotten more pictures throughout the build but it’s kind of hard when you get side tracked with customer work and not really ever thinking of making a Vital build post. But here’s what I have!


Here are the before pics!



Now let’s get this show on the road and see what I have gotten myself into on this restoration job


YIKES! First up, let me make the save of the day. Broken off fork bleeder screw. Managed to tap a small Phillips into what was left of it and gently turn it out.



Round 2 save of the day coming up. Had to get these rounded out fork pinch bolts out. Impact happy much? They were mucho mucho tight. Stupid tight. Managed to beat a 9mm socket onto the heads and get them out with an impact.



It’s just getting better isn’t it! DOPED up much?? Wow😂 No wonder why the kill switch wouldn’t work. Managed to save this, I didn’t happen to get any after pics. Quite a few of the wires were damaged. Had to be snipped, and connected to a new connector (Thanks Honda for using the same connectors on multiple different bikes, managed to find one in some old pile of wiring at work)



Frame job up next, along with cleaning the engine as well and going through the engine to see if it’s trashed out and worn out.


That’s more like it!


The black krylon had to go on the works PC!



Laced and trued up some Excels for it


Went with the Polisport restyle kit! Managed to snag it off Motosport for $110. Waiting on fork seals to arrive now.


About forking time! Fork seal, service, and revalve time.



Shock seal replacement, service & cleaning, shock bladder replacement, and revalve time!








Jake @ Strict Designs Co in Austin, Tx whipped up some graphics!



If you know you know! Nothing like the smell of Klotz 32:1, 50/50 VP110 with 93. Prefer Super Techniplate but only had access to Benol at the time



Now time for the completed pics, even though I didn’t capture a lot of the small stuff! Shoutout to Hoosier Tire West for the hook up not only on the moto tires, but also flat track tires for my 450 flat tracker!






Also if you guys want to follow any of my other work I can be found as Harris Built Co on both Instagram and Facebook where all of my customer work can be found.

Thanks, Tyler