Posts
309
Joined
11/22/2010
Location
CA
US
Edited Date/Time
2/20/2015 6:03pm
Finally got the build portion of this project completed. To refresh everyone's memory, I started with a 2009 CRF250R frame
(my favorite Aluminum version), and an engine based on the 2000 CR250 cylinder and cases. The goal of this project was
to build (to the best of my ability and budget), a bike like Team Honda would field if they were still racing two strokes. The
bike was scratch built with all new parts. Final weight with all fluids but no gas is 198 lbs.
With the build portion done, it's time to start developing the bike. This is the part where I get to grind out laps to work out the
bugs and to dial in the engine and suspension - should be fun.
Enjoy the pictures.
dogger
(my favorite Aluminum version), and an engine based on the 2000 CR250 cylinder and cases. The goal of this project was
to build (to the best of my ability and budget), a bike like Team Honda would field if they were still racing two strokes. The
bike was scratch built with all new parts. Final weight with all fluids but no gas is 198 lbs.
With the build portion done, it's time to start developing the bike. This is the part where I get to grind out laps to work out the
bugs and to dial in the engine and suspension - should be fun.
Enjoy the pictures.
dogger
I take it the new front brake hose is in the mail??
See you have an NOS Dunlop 756 front tire on it. Was my favorite front tire for 15 years and it was a sad day when Dunlop discontinued them. Never thought I'd ever find another front that I liked as much as the 756, until I tried the new Dunlop MX32 front tire. Happy to say that it is better than the old 756.
The Shop
And thanks for the how to rebuilt CR250 motor on the other forum. That was really helpful for me.
That thing is awesome ! Awesome job man much respect
Bruce372, actually that is a new front brake hose. I bought it as a spare when I was building my CR500, so it's been sitting
around the shop for a few years. It does look kinda tired in the picture, though. Originally, I had Heil make up a pair of SS
lines. Unfortunately, the front line was about 2-3" too long so I went back to stock. I still have the SS line in the back.
Honda11, that second switch is to swap ignition maps. The bike has a Vortex X10 programmable IC, so I can switch between
two stored maps on the fly.
CamP, I still have a stash of 756RRs that I have kept in a climate controlled space. Great tires but with a super short life. I've
also heard the raves about the new MX32, so when these 756s are gone, I won't feel so bad switching.
charley586, glad I was able to help with your engine rebuild. Don't think the PC silencer was a bolt on affair. I had to cut the
inlet pipe off the can, then reshape the end to change the angle then weld it back together. I also had to fab up a special
bracket that mounts using the rear fender bolt to get everything tucked in. The pipe on this bike is for a 2000 and the shorty
silencer is for a 2007. Luckily, all the exhaust tuning for a two stroke takes place in the expansion chamber. I'll take the side
panel off and take a picture of the set up. Maybe you can come up with something you like better for your bike. By the way,
I'm a big fan of FMF pipes. If they made a "Factory Fatty" for a 2000 CR, I'd probably have one on this bike along with their
sweet Ti2 silencer. Conversely, PC just came out with a trick new CF shorty silencer, but in typical PC fashion, it's only
available for KTMs, YZs and the KX80 - No love for anything but current production bikes.
dogger
Sorry for stealing your pic (and my bad english I'm fron the great french white north). Knowing before that the PC shorty pipe from a 2007 would have fit the PC factory pipe and I would have modified the silencer like the second pic. Putting the little triangle that I've build and cutting the end parts. I prefer the factory look but I already had the FMF exhaust and didn't like the PC silencer with the end pipe with the little pipe going down. It give me a reason to get one next year but I have to finish this AF first.
How did you approach the valving on the suspension? I know you need more damping and stiffer springs but by how much... I know for sure the stock setup of the 250F would'nt be good.
If you prefer you can PM me so I don't steal your thread.
Here are some pictures I took of the silencer set up. The goal is to mount the silencer so that it tracks along the same path as
original. If you look at the picture of mine with the side panel on, you can see the silencer lines up with the rubber bumpers. To
make this happen, I welded on a raised captured nut mount for the front tab and fabbed up an extension with a spacer for the
aft tab. Then I had to cut the inlet pipe like I mentioned before to get the allignment needed to use a silencer intended for a gen
3 frame to fit on a gen 4. This same method can be used to fit any brand silencer as long as the silencer was originally for the
same make of bike.
As far as the suspension, I started from scratch there so I don't really have any useful info to pass on what to do with the OE
Honda stuff. When I placed the order with PC for this suspension, I told them everything about the project so they could set
up the components accordingly.
Hope this helps.
Thanks Dragoo and scooter. Hey scooter, the CR500 is getting the same graphics treatment as this 250. You're avatar will
become a collectible soon.
dogger
I always liked the FMF factory fatty on 250 smokers, I never liked the one PC since it was pipey and the brackets always snapped off the silencer.
since the 2000 engine is a similar layout to the RM and YZ smokers, I bet you could whip up a new spigot and weld it to one of those pipes if they fit the frame.
really, really cool bike.
Pit Row
Bruce372, I saw that thread. I got this brake set up the hard way. When I first started riding my '08 CR500, it had the OE
brakes front and rear. It had been a bunch of years since I had ridden a 500 and I didn't appreciate how fast I was going
until I went to brake for a corner. Luckily, there wasn't anything hard on the other side of the berms I kept riding up and
over as I blew the corners. So one of the first changes for that bike was the 270mm CRF Stuff rotor. IMO, the 270mm
size is a perfect combination of stopping power and brake feel, so naturally I put one on this 250 as well.
AJ, that means a lot. Thanks for the inspiration.
dogger
I was finally able to finish the rebuild of the silencer ans install it quickly to see how it look. The idéal was to follow the natural Line of the original silencer.
Charley, looks like you have that silencer tucked in nicely. Keep in mind that if you run into problems with cracking or metal
fatigue due to vibration and the single mounting point, you can try a shorty silencer. Less weight and less length will help.
dogger
125 and 500 next?
Deserves to be posted again.........
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