2007 CR 250 - The build begins! The build is FINISHED!

Hoodie
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ID US
3/19/2013 12:25am
Where did you order the pipe from?
AS64
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3/19/2013 2:02am
You've convinced me to try out the ODI Handlebars. Definitely a cool concept behind them.
MOTO120
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MOTO, IL US
3/19/2013 5:26am
Hoodie wrote:
Where did you order the pipe from?
Motoman is the USA importer I ordered mine from....shoot him an e-mail.

info@motomandist.com
MOTO120
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MOTO, IL US
3/19/2013 5:27am
AS64 wrote:
You've convinced me to try out the ODI Handlebars. Definitely a cool concept behind them.
Awesome! I thought the same thing, pretty cool concept and makes sense.

The Shop

Huevos
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3/19/2013
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Spokane, WA US
3/19/2013 7:48am
This is my first post, but I've been lurking on this site for a few years now. Just wanted you to know that your bike is one of the sickest I've ever seen. This thread has kept me anxious for updates the past few months. You must have a really good career, considering how much you seem to be investing in this bike. Thanks for the updates man, and hopefully things continue to go smoothly for you on the build.
MOTO120
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MOTO, IL US
3/26/2013 10:55am
No pictures :thumbsdn: for this update but thought I'd post some general things that are going on.


1) Ordered an APT SmartCarb


2) Seat foam that was on the bike was terrible (imagine that), so I ordered new seat foam from MotoSeat


3) Found out that Talon Carbon front hubs do not take the same bearings as a standard Talon front hub.....patiently waiting on the correct ones to arrive


4) Ordered the remaining plastics for it (side number plates and shrouds)


5) Received the new spokes, nipples, and spacers....now just waiting on the rims to show up so I can build the wheelset (on order, just waiting)


6) Thought I found a great deal on a Hinson Inner Hub to complete my clutch system (already have a Hinson basket and Hinson pressure plate). Purchased an almost new one off eBay from a TRX450 (quadzilla haha), after looking on Hinson's site I found out that the TRX 450, CRF 450, and CR 250 all use the same hub......well I received it and it wasn't what it was suppose to be. SO, I shipped that back and now looking for another Hinson Inner Hub.....


7) Took APBT's advice and ordered the new $6 servo motor off eBay rather than spending the $170 on an entire new Honda OEM servo motor assembly. Suppose to be getting the new servo motor today in the mail and hope to get all that back together soon.



I either HAVE or HAVE ON ORDER everything needed to complete this project with the exception of anything/everything braking related (oh yeah, and that inner hub). I have the master cylinders (front and rear) torn apart and cleaned, now I just need to order the re-build kits for them. Next would be figuring out what I want to do about the calipers (front and rear), as the ones that came on the bike are pretty nasty (the pistons literally have rust on them)...I think I might search out some newer CRF ones on eBay...anyone know if '09+ calipers will mount up to this bike without problems? Updates with pictures hopefully in the coming week or two.


Thanks for looking,

Blake
mxtech1
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1954
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7/21/2011
Location
Galesburg, IL US
3/26/2013 3:38pm
Have the calipers blasted with a walnut shell media. They will come out looking like new! Then just order news seals and pistons for the calipers. This method also works great on the outside of enginer cases.

I ride alot of D17 tracks so I'm hoping to see you out with this bike this year!! Awesome build man
MOTO120
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MOTO, IL US
4/2/2013 6:18am
A couple (probably) "boring" pics but thought I'd share


Old servo motor on the left, new one on the right....would you say it was time to be replaced haha




What the inside of the servo motor housing looks like




I am going to re-use the wiring harness I have, just took all the old nasty tape off and re-wrapped everything. This is the pile of tape that came off...there was A LOT!




A couple before and after pics of some brake components (after I cleaned them)....all the re-build components should be in this week Smile










Couldn't help but share 1 fun pic haha

MOTO120
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MOTO, IL US
4/8/2013 5:52am
Sorry, kinda slacked on my picture taking over the weekend while working on the rebuilding the rear master cylinder, rear caliper, and front master cylinder. Should be getting my rims this week (I hope) as well as inner hub and new clutch springs.....I'll post updates as it comes along.

Parts involved to re-build front master cylinder


Never knew this, but there is a small C-Clip below that clear bubble piece....



Parts involved to re-build rear master cylinder


Rear master cylinder all bolted up (used Fasst Co rear brake clevis and rear brake return spring kit)
MOTO120
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MOTO, IL US
4/8/2013 6:44pm Edited Date/Time 4/9/2013 5:22am
Repost
MOTO120
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1343
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3/21/2010
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MOTO, IL US
4/17/2013 5:54am
A couple updates

Got everything to assemble the wheels (they are now at Hall's Cycles getting true'd and new rubber put on)








Finally got the little servo motor gear from Shanghai. I had ruined the original gear trying to get it off the original servo motor. After TONS of searching online, this gear was what I THOUGHT was going to be the closest thing available....turns out it worked perfect! So with the new $7 servo motor and $2 gear working as they should, I saved myself from having to buy the entire new $175 OEM servo motor assembly! The new gear wasn't the same length, but found out that doesn't matter as long as you press it on the correct distance. Also, I put a little extra sealant around that O-Ring in the 3rd picture to help keep weather/water out and prevent a rusted servo motor again.










Servo motor was this:
http://www.ebay.com/itm/120946913917?ssPageName=STRK:MEWAX:IT&_trksid=p…

Gear was this (took about 3 weeks for delivery):
http://hobbyking.com/hobbyking/store/__9252__Pinion_Gear_2_3mm_0_4M_12T…
SwapperMX
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2134
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6/16/2010
Location
AU
4/18/2013 4:47am
Wow, getting close now. So sweet. You won't want to ride it when it's finished!!
MOTO120
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3/21/2010
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MOTO, IL US
4/20/2013 8:44pm
Made quite a bit of progress over the past several days....hope you enjoy :-)!

Received my new seat foam from MotoSeat (had received my MotoSeat seat cover a while back). The bike previously had a very old/worn out (imagine that) SDG seat, I'm used the old seat base and combined it with the new MS foam and cover

Old seat foam


New seat foam with beginning of seat cover install


Finished product....MotoSeat seat cover and MotoSeat seat foam!



Randomly decided to clean up the fuel tank and take the petcock off. I shouldn't be surprised, but lets just say I'm glad I decided to take a look!




Got my graphics in the mail from 180 Decals.....SO sick!



Got my wheels back from Hall's Cycles...all true'd up and fresh rubber (just as a side note, I decided to use the Motion Pro "lite" rim locks....hopefully they work well haha)




And finally.........made some progress on the bike!!!







jhansen510
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GREENFIELD, MN US
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3559th
4/20/2013 8:53pm
Fuck and shit man! Let me be the first to tell you that you are going to make alot of people wish they had 2 strokes again! I bet you cant wait to ride that thing. But I bet at the same time you are dreading putting the smallest of scratches on that beauty!
million
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62
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11/12/2012
Location
NZ
4/21/2013 6:28pm
Love this bike!
Jhansen's right. I want a 2st again!
Travis_Hudson
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Bentonville, AR US
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4/22/2013 9:18am
sweet!!!!! Where did you get the yellow dunlap stickers??? Those are hard to come by. Wink
G Force
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Winnipeg CA
4/29/2013 8:04am
Beyond words...Just a badass build. Very well done!
Hoodie
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ID US
4/29/2013 3:53pm
sweet!!!!! Where did you get the yellow dunlap stickers??? Those are hard to come by. Wink
X2
jhansen510
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GREENFIELD, MN US
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4/30/2013 1:32pm
Are those not just colored on with a paint pen?
Travis_Hudson
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4/30/2013 2:59pm
jhansen510 wrote:
Are those not just colored on with a paint pen?
No, I worked at the KTM race shop in southern CA for awhile, and all the factory Dunlaps came with yellow stickers for the tires, and we had stacks of stickers for media related bikes for alittle extra attention on those bikes. Here is my 2005 KTM 250sx, and you will notice a letter missing or two. Wink
Travis_Hudson
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4/30/2013 3:00pm
jhansen510 wrote:
Are those not just colored on with a paint pen?
No, I worked at the KTM race shop in southern CA for awhile, and all the factory Dunlaps came with yellow stickers for the tires, and...
No, I worked at the KTM race shop in southern CA for awhile, and all the factory Dunlaps came with yellow stickers for the tires, and we had stacks of stickers for media related bikes for alittle extra attention on those bikes. Here is my 2005 KTM 250sx, and you will notice a letter missing or two. Wink
missed the pic........
MOTO120
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MOTO, IL US
4/30/2013 6:09pm
sweet!!!!! Where did you get the yellow dunlap stickers??? Those are hard to come by. Wink
Hoodie wrote:
X2
Sorry guys it took me a while to reply to this. Yes, they are actual tire stickers (like Travis said, like you would see on media and/or factory bikes) not just a paint marker. Have a relationship with Dunlop from previous years racing sponsorships and they were willing to help me out :-).
Travis_Hudson
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Bentonville, AR US
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4/30/2013 11:52pm
sweet!!!!! Where did you get the yellow dunlap stickers??? Those are hard to come by. Wink
Hoodie wrote:
X2
MOTO120 wrote:
Sorry guys it took me a while to reply to this. Yes, they are actual tire stickers (like Travis said, like you would see on media...
Sorry guys it took me a while to reply to this. Yes, they are actual tire stickers (like Travis said, like you would see on media and/or factory bikes) not just a paint marker. Have a relationship with Dunlop from previous years racing sponsorships and they were willing to help me out :-).
Good man, looks supe sweet, I have torn my 04 cr down to the frame to start my build as well, while I don't think it will be near as trick as yours....you have def. Given me some major inspiration, well done!
MOTO120
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1343
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3/21/2010
Location
MOTO, IL US
5/5/2013 4:21pm
A couple more small updates...things aren't going so quickly as the due date for our first baby is quickly approaching :-)

Got a 280mm front rotor and the rear rotor installed



Got the petcock all cleaned up and put back together....with Ti pieces of course haha



Got a new OEM kill with...the old just didn't look so good, imagine that


Made a little aluminum adapter bracket in for the newer CRF style plate...turned out OK



Just doing a little maintenance
davis224
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Cornland, IL US
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182nd
5/7/2013 8:15pm
That's one fancy stand in that last pic!
MOTO120
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MOTO, IL US
5/8/2013 5:18am
davis224 wrote:
That's one fancy stand in that last pic!
Thanks....I seem to think so too Mr. Davis haha
motofab36
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Cowden, IL US
5/8/2013 6:19am
Are they on the market yet?
MOTO120
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MOTO, IL US
5/8/2013 7:25am
motofab36 wrote:
Are they on the market yet?
Note quite yet Wink
Huevos
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916
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3/19/2013
Location
Spokane, WA US
5/8/2013 1:15pm
Maintenance? The bike hasn't even been finished or ridden yet! What kind of maintenance could you possibly be doing? This is a great project you have going on, man. I'm looking forward to seeing it finished soon.

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