Honda XR250R build e-start- titanium

Tumic
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Tumic 10/22/2021 12:00pm
10/22/2021 12:00pm
Al259 wrote:
Here’s another cool thing I found in 1998 there was actually a XR250 in the enduro world championships that won its class. Here some pics of...
Here’s another cool thing I found in 1998 there was actually a XR250 in the enduro world championships that won its class. Here some pics of the bike. Interestingly the bike looks form the external quite stock.







In -98 it was more or less just Honda that made the 250 4t’s, so we can call it a one brand class. My old team manager rode the same class and came second one year on a xr 250.
YZed250
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YZed250 11/3/2021 1:30pm
11/3/2021 1:30pm
Al259 wrote:
Here’s another cool thing I found in 1998 there was actually a XR250 in the enduro world championships that won its class. Here some pics of...
Here’s another cool thing I found in 1998 there was actually a XR250 in the enduro world championships that won its class. Here some pics of the bike. Interestingly the bike looks form the external quite stock.







Tumic wrote:
In -98 it was more or less just Honda that made the 250 4t’s, so we can call it a one brand class. My old team...
In -98 it was more or less just Honda that made the 250 4t’s, so we can call it a one brand class. My old team manager rode the same class and came second one year on a xr 250.
Yeah, in Australia we had the TTR250, KLX250 and DRZ250.
Ben Grabham won multiple Australian Enduro Championships on the a relatively stock XR250. He was always a gold-medal ISDE trophy rider, and may have won the class at that event too, mostly on XR250s.
Australia was also the home of the ThumperNats, one of the greatest/most popular 4-stroke MX championships through the 90s and into the 2000s with factory-level 250F and 400 to 650 four-stroke racing.
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Pirate421
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Pirate421 11/4/2021 4:16am
11/4/2021 4:16am
This is an awesome thread. I grew up on XRs in the 90s. Never could believe how awesome they’d be nowadays, you really couldn’t kill them. We must have ran hundreds of gallons of gas through them and never knew about changing oil or air filters and they always ran haha. really cool builds.
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Al259
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Al259 11/6/2021 4:10pm
11/6/2021 4:10pm Edited Date/Time 2/2/2023 8:47pm

Haven’t updated In a while. It’s the beginning of winter here. The weather is cold and wet. Haven’t done much last few weeks. Last thing was pulling the shock appart and recording the stock settings and comparing them to other settings that I have done in the Past. That way I have some time to think of what direction I want to go.




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The Shop

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Al259
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Al259 11/9/2021 1:27pm
11/9/2021 1:27pm
I‘ll be using a Yz bladder cap to increase the nitrogen volume in the shock. Hoping to gain some sensitivity and a bit less fade if the shock is run in a high temperature setting.


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jbonemalone
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jbonemalone 11/9/2021 4:52pm
11/9/2021 4:52pm
There’s attention to detail and then there’s this.
I loved my klxs and Xrs. Larry Roesler had some really neat klx stuff way back when.
Those Xr 250s were made of some indestructible materials I suppose because they just wouldn’t die !!
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Al259
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Al259 11/18/2021 1:14pm
11/18/2021 1:14pm
So I’ve come across something worth posting. While I’m still working on the rear shock configuration. I noticed that Yamaha used 03-04, two different bladder caps in the bikes. The 03 version has a bit bigger volume. The 03 also uses a alloy valve core. This also the cap I will be using as it is more suitable for a lighter rider.





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Al259
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Al259 4/18/2022 1:41pm
4/18/2022 1:41pm
So after a Long break and lots of headache’s the bike is running. I still need to clean up the wiring abit. Next. Step is to go for dlc coating on the forks and shock. The front springs need to be shortened a bit and the rear shock is getting a goldvalve. And the extended bladder.


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Al259
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Al259 4/18/2022 1:49pm
4/18/2022 1:49pm
For a while now I‘ve been fiddling around with different carb setups. As seems my wife prefers the XR250R ME08 carb set up. With a little modification it does what is needed. Because of the electric start there is a 5mm spacer needed.





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Rickyisms
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Rickyisms 4/19/2022 4:32pm
4/19/2022 4:32pm
I feel like I’m watching the engineers design a new bike.
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Al259
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Al259 4/21/2022 10:53am
4/21/2022 10:53am Edited Date/Time 4/27/2022 9:37pm
I got my self a set of theses warp 9 Rim Locks, I must say I don’t now what the hype is about with these things. Weight wise they are not really an advantage.


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Al259
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Al259 4/28/2022 2:55pm
4/28/2022 2:55pm
Thanks man. While the suspension stuff is gone for dlc, I checked my racetech gold valves and noticed that the internet access code for the rear shock was missing 😢. I contacted the tech support hope they can help me out. Anyone had something similar happen to them?


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Al259
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Al259 4/29/2022 2:08pm
4/29/2022 2:08pm Edited Date/Time 6/27/2022 10:26pm
So since Racetech does not seam to have any interest in helping me, I think others will be going through the same issues. I just post this valving chart here.


These charts work for the gold valve pistons pretty well. Just in case anyone needs a chart there you go.
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Al259
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Al259 4/30/2022 4:02am
4/30/2022 4:02am
Started valving the front, and checked some stuff for the rear shock. Changing the Sealhead to a aftermarket one seams to save another 100g.
I‘m still checking if the big base washer can be made of 7075 instead of steal.



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Al259
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Al259 4/30/2022 6:07pm
4/30/2022 6:07pm
Dual compound seals showed up today, awesome seals. They are really good at reducing friction. Gives a little more sensitivity to the fork for low Speed stuff.


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Al259
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Al259 5/4/2022 10:35pm
5/4/2022 10:35pm Edited Date/Time 9/5/2022 1:35pm
Base Valves for the front are done. During the process of sorting the valving I noticed that racetech, like everyone else, has gone to bigger pistons and ports over the years. The kit that I have doesn’t work for the newer size face shims.

Carb clears the Starter Motor better with the spacer.



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Al259
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Al259 5/9/2022 2:04pm
5/9/2022 2:04pm Edited Date/Time 5/29/2022 3:53pm
While waiting on the suspension parts, I‘m swapping the stock exhaust studs for titanium ones, it all adds up in the end. 😊




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Pit Row

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Al259
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Al259 5/25/2022 1:36pm
5/25/2022 1:36pm
I‘m still waiting on my dlc parts. The guy doing my dlc is not as responsive to emails as I wish. Now after three weeks of waiting on the dlc stuff he tells me that he can’t remove one of the lugs🤦🏼.
Meanwhile I did some playing around with stuff I had in the workshop. I just swapped the front tyre from Dunlop to Michelin and because the another 400g.


Then I found alloy rear axle nut, so I swapped the Ti nut for the alloy also saving 3-4gs. Now I only have to shorten the rear axle to the correct length.





Got some more Ti And alloy bolts in the mail

Slowly I‘ll be swapping the last steel bolts for TI and alloy.


I swapped the tail light hardware from steel to alloy





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Al259
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Al259 5/26/2022 3:18am
5/26/2022 3:18am
Bit by bit the steel bolts are all disappearing.



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Al259
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Al259 5/31/2022 1:47pm
5/31/2022 1:47pm
Today I had a little time in my hands. Put some stuff on the scale and found another couple of grams I can save. First of the shock Piston.



Then I‘ll be going to a mikuni TM33-8012 carb that will save me another 291g.



That’s another 301g shaved of the bike.
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Al259
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Al259 6/3/2022 5:25am
6/3/2022 5:25am Edited Date/Time 6/12/2022 10:45am
Found another couple of grams that I could save by going to a galfer wave floating rotor, good side effect is that the floating rotor improves the stopping power because there is almost 100% contact area.

Old 560g
New 490g
-70g






There‘s a nice set of Ti Bolts coming for the Rotor too.




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Al259
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Al259 6/12/2022 10:43am
6/12/2022 10:43am Edited Date/Time 6/12/2022 3:25pm
Found some more grams to save, replaced the base valve nut and Base washers with Ti.-2,45g



Base plate for the shock in7075 alloy.
-24,04g





Alloy Small timing plug to replace the oem steel part. -8,04g




With the Ti brake rotor bolts and the rotor it’s self it’s another 120g off the bike. Adding the carb it adds up to 0,5kgs that’s really cool.
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Al259
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Al259 6/16/2022 6:04am
6/16/2022 6:04am Edited Date/Time 6/16/2022 6:14am
Some details












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ace402
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ace402 6/18/2022 6:56am
6/18/2022 6:56am
Great job! Any idea of how much weight you have saved overall so far?
Al259
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Al259 6/18/2022 12:14pm
6/18/2022 12:14pm Edited Date/Time 6/27/2022 6:47pm
ace402 wrote:
Great job! Any idea of how much weight you have saved overall so far?
Unfortunately not, because I was not as consequent with checking weights and noting them as I would have liked to have been.I know its going to be around 102-103 kgs when done. That’s pretty good.
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Al259
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Al259 6/26/2022 3:36pm
6/26/2022 3:36pm
Finally got my Suspension stuff back from DLC



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mitch199
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mitch199 7/5/2022 11:19pm
7/5/2022 11:19pm
Awesome stuff. Sitting at home with Covid in 2022 and now wanting to go and buy a heap of Ti for my bike... sickest XR250 on earth I would say?
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Al259
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Al259 8/19/2022 5:33am
8/19/2022 5:33am Edited Date/Time 9/2/2022 12:14am
After a long Time of not beeing able to work on bike I finally got a few minutes today. Cut out some carbon fiber tank mounts. And worked on making a carb adapter.









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Al259
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Al259 8/25/2022 3:02pm
8/25/2022 3:02pm Edited Date/Time 9/1/2022 10:22pm
Carb is fitted, got the new domino throttle today. Jetting still seams minimally off.




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