2002 Honda CR250R Rebuild (finished)

The engine is finally ready to be put back in to the frame

Started working on the exhaust pipe today. Because new exhaust pipe is not in the budget I'm trying to make old one look good again.

Here's the pipe before I started





This is how the pipe looks after few hours of polishing. I'm still not 100% happy with the result but it's getting there

I got some metal polish and used it on the pipe. It's starting to look pretty good







removed old grip tape on the frame. I still need to do the same on the other side



I also found a pic from one of the team CAS Honda bike's from 2002. This one has bit different graphic kit than my brothers bike

I continued cleaning the frame today.

Before:



After:

We had a major setback on this build (read it from here) and had to take some time off from it. Last weekend we where back on the build and got the new seat cover installed. It came out looking pretty good. There is also new crankshaft on its way and hopefully it will arrive this week.

Got the new crankshaft yesterday and changed it today









Engine back in the frame



HRC swing arm



This is where I'm at after today's work

Changed new linkage bearings today







Marking on the top of the shock. I don't know is this a stock shock or something else?





Shock mounted to frame



Engraving on the rear wheel. All the engravings on the bike seem to have number two on it



You can still see the race inspection marking on rear rim



To be continued...

Got some more assembly work done today

Exhaust silencer was in pretty poor condition.






New silencer would be nice, but we are trying to keep cost down and I ended up rebuilding old one. I had to cut a piece off from silencer outer tube because rivet holes where gone. I might have to get some extension welded to middle pipe to get the joint seal properly. I have to see how it fits when I get sub frame back from welder. It had some some small cracks which had to be welded.

What is wrong with the Biltema brake disc? It has been working good so far.

Got the subframe back from welder and the build is now 99% complete

I don't know if the Lithuanian guy is still in graphics business. I ordered graphics for the Honda project almost year ago from him. I found him trough Ebay when I ordered decal kit for my KTM. I sent his email address to you in private message.

I got bike ready late last night and hauled it to local motorcycle exhibition early this morning. It's displayed at local motor club stand for whole weekend. I will post some better pictures we get the bike back home. We did enter the bike to peoples choice award competition in the exhibition. We will see how that goes =D Most of the bikes in exhibition where Harleys...

Good luck with your build! It would be nice to see some pictures of your project.

Here's pictures of a finished bike











Bike and the builders



Short video of a first test ride

https://dl.dropboxusercontent.com/u/3604584/2015-03-15%2015.11.40.mp4

There is still few small things to do. Biggest issue are front forks which are bit too harsh in first part of the stroke. Does anyone have good tips for setting up the forks for 65kg (143lbs) rider ?

Added some carbon fiber sticker to protect sub frame under the seat



Rubber coolant hose added to seal exhaust pipe and silencer joint





Now she is ready to get dirty

Got a replica HRC clutch cover from a fellow VitalMX:er Mad Mike #81. It's really good quality and looks great!