1996 CR250 McGrath Replica Rebuild

MadMatt579 12/17/2014 4:14am
12/17/2014 4:14am
Here's my 94.





MCfan4life
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MCfan4life 12/17/2014 4:16pm
12/17/2014 4:16pm
MadMatt579 wrote:
Here's my 94. [img]https://p.vitalmx.com/photos/forums/2014/12/17/74108/s1200_20141202_204822.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2014/12/17/74109/s1200_20141210_175907.jpg[/img]
Here's my 94.





Nice work on the engine! Are they aqua blasted?
MadMatt579 12/18/2014 4:08am
12/18/2014 4:08am
Yep, hydro blasted. same guys that did 100PerCentMX's engine. My home soda blasting works well but was still not getting out the aluminium stains. no problems with staining now.
100PerCentMX 12/26/2014 8:24pm
12/26/2014 8:24pm


Got the bottom end built today.

The Shop

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notme
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notme 1/9/2015 7:17pm
1/9/2015 7:17pm
I just read on a fb page a guy mounted up a brake petal off a 14' yz450, says it fits perfectly except the return spring lug needs relocating.

If anyone has the opportunity to check this, report back to us. This would be a damn fine find!
Unless there is another option.
JohnnyOfast
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JohnnyOfast 1/9/2015 10:14pm
1/9/2015 10:14pm Edited Date/Time 1/9/2015 10:28pm
Don't know if it's been mentioned but the titanium foot pegs off my '07 YZ450F bolted right up to my '96 frame, springs pins and all. Would hold true for any late model YZ250/450F at least up to '09 and maybe later, the '08's & up are even wider.

Anybody know of a suitable substitute for the brake return spring? another part no longer available.

MCfan4life
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MCfan4life 1/9/2015 11:30pm
1/9/2015 11:30pm
JohnnyOfast wrote:
Don't know if it's been mentioned but the titanium foot pegs off my '07 YZ450F bolted right up to my '96 frame, springs pins and all...
Don't know if it's been mentioned but the titanium foot pegs off my '07 YZ450F bolted right up to my '96 frame, springs pins and all. Would hold true for any late model YZ250/450F at least up to '09 and maybe later, the '08's & up are even wider.

Anybody know of a suitable substitute for the brake return spring? another part no longer available.

Very interesting and gives plenty more footpeg options. Thanks for sharing!
pcpa91
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pcpa91 1/17/2015 3:48pm
1/17/2015 3:48pm
Hi guys.. I have a CR 125 1997 and i have a CRF 2014 front fender and number plate to put. My question is.. Which most recent rear fender i can put? Anyone can help me?
100PerCentMX 1/17/2015 3:56pm
1/17/2015 3:56pm




I got my 285cc big bore kit back from RPM and finished building the top end.
david.murello 1/18/2015 12:59pm
1/18/2015 12:59pm
MCfan4life wrote:
OK guys, it's time to start a thread on my 96 CR250 McGrath replica rebuild. I'm gonna need any expert help I can get on everything...
OK guys, it's time to start a thread on my 96 CR250 McGrath replica rebuild. I'm gonna need any expert help I can get on everything from cleaning/renewing parts through to sourcing 'special' bits and pieces. So all you 2 stroke lovers and experts (The Pipe, Newmann, 917, Pat327, DB, etc) please feel free to comment any time with ideas guys.

This bike has already been rebuilt once. I picked it up looking like this:



and rebuilt it into this:



But being the fussy bastard that I am, I am now rebuilding it again to more accurate detail. The first rebuild was a bit of a rush as I wanted the bike to be complete when MC came to Australia for SuperX in 2008. That's where the photo was taken with Jeremy. My best mate Jake and I wheeled it straight past security and into the pits!
Hi, I'm David from Italy and I have a Cr 250 1996 which will replica Mcgrath.
I want to insert rear brake disc 240 and I would like to know if I can transfer brake Cr 97-99 on 96 swingarm.
Thanks for the help.
JIM77
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JIM77 1/20/2015 2:55am
1/20/2015 2:55am
100PerCentMX wrote:
[img]https://p.vitalmx.com/photos/forums/2015/01/17/77208/s1200_image.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2015/01/17/77209/s1200_image.jpg[/img] I got my 285cc big bore kit back from RPM and finished building the top end.




I got my 285cc big bore kit back from RPM and finished building the top end.
What fasteners are you using for assembly of the right side case? I'm guessing stainless cap screws? Are you just getting them from a bolt supplier?

I think the water pump and reed block ones from Honda are high tensile, not sure why. Maybe someone else can confirm.

Engine looks mint mate.
JIM77
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JIM77 1/20/2015 2:56am
1/20/2015 2:56am
MCfan4life wrote:
OK guys, it's time to start a thread on my 96 CR250 McGrath replica rebuild. I'm gonna need any expert help I can get on everything...
OK guys, it's time to start a thread on my 96 CR250 McGrath replica rebuild. I'm gonna need any expert help I can get on everything from cleaning/renewing parts through to sourcing 'special' bits and pieces. So all you 2 stroke lovers and experts (The Pipe, Newmann, 917, Pat327, DB, etc) please feel free to comment any time with ideas guys.

This bike has already been rebuilt once. I picked it up looking like this:



and rebuilt it into this:



But being the fussy bastard that I am, I am now rebuilding it again to more accurate detail. The first rebuild was a bit of a rush as I wanted the bike to be complete when MC came to Australia for SuperX in 2008. That's where the photo was taken with Jeremy. My best mate Jake and I wheeled it straight past security and into the pits!
david.murello wrote:
Hi, I'm David from Italy and I have a Cr 250 1996 which will replica Mcgrath. I want to insert rear brake disc 240 and I...
Hi, I'm David from Italy and I have a Cr 250 1996 which will replica Mcgrath.
I want to insert rear brake disc 240 and I would like to know if I can transfer brake Cr 97-99 on 96 swingarm.
Thanks for the help.
Yes that will work, you need to use a Yzf banjo bolt though, at the caliper to clear the swing arm.
MCfan4life
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MCfan4life 1/20/2015 1:47pm
1/20/2015 1:47pm Edited Date/Time 1/20/2015 1:48pm
david.murello wrote:
Hi, I'm David from Italy and I have a Cr 250 1996 which will replica Mcgrath. I want to insert rear brake disc 240 and I...
Hi, I'm David from Italy and I have a Cr 250 1996 which will replica Mcgrath.
I want to insert rear brake disc 240 and I would like to know if I can transfer brake Cr 97-99 on 96 swingarm.
Thanks for the help.
Full details of this update are listed in this thread somewhere David. But yes a 97-99 CR250 rear disc can be mounted. You will also need the 97-99 CR250 caliper carrier and a late model YZ/F banjo bolt to complete the job. The standard CR banjo bolt is a raised hex head and it hits the swingarm with the later model caliper carrier. The YZ banjo bolt is a counter sunk Allen bolt.

Important: DO NOT order 97 CR125 parts as these will be the same as your 96 CR250. 97-99 CR250 or 98-99 CR125 parts must be used.
100PerCentMX 1/20/2015 11:32pm
1/20/2015 11:32pm
100PerCentMX wrote:
I purchased this complete stainless steel bolt kit from a US seller on ebay. All the bolts in this kit are high tensile, see here:

http://www.ebay.com.au/itm/HONDA-CR250-455-PIECE-POLISHED-STAINLESS-STE…
OnedayWhip wrote:
Those are all cap screws though bud, not like Honda flanged bolts.
Correct bud, with washers.
david.murello 1/21/2015 7:18am
1/21/2015 7:18am
100PerCentMX wrote:
I purchased this complete stainless steel bolt kit from a US seller on ebay. All the bolts in this kit are high tensile, see here:

http://www.ebay.com.au/itm/HONDA-CR250-455-PIECE-POLISHED-STAINLESS-STE…
Hello. Many thanks. Now I understand and I have to find the correct model banjo bolt Yz.
Yes, I'm aware that the same group has 97 125 rear brake.
MCfan4life
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MCfan4life 1/21/2015 4:04pm
1/21/2015 4:04pm
david.murello wrote:
Hello. Many thanks. Now I understand and I have to find the correct model banjo bolt Yz. Yes, I'm aware that the same group has 97...
Hello. Many thanks. Now I understand and I have to find the correct model banjo bolt Yz.
Yes, I'm aware that the same group has 97 125 rear brake.
Any late model YZ or YZF should be fine, but I used one off my 2008 YZ250.

Pit Row

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MCfan4life
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MCfan4life 1/21/2015 4:05pm
1/21/2015 4:05pm
100PerCentMX wrote:
I purchased this complete stainless steel bolt kit from a US seller on ebay. All the bolts in this kit are high tensile, see here:

http://www.ebay.com.au/itm/HONDA-CR250-455-PIECE-POLISHED-STAINLESS-STE…
OnedayWhip wrote:
Those are all cap screws though bud, not like Honda flanged bolts.
100PerCentMX wrote:
Correct bud, with washers.
Personally I hate allen head bolts and prefer the OEM hex head bolts. But that's just me!

Engine is looking good Paul.
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JohnnyOfast 1/23/2015 11:52am
1/23/2015 11:52am Edited Date/Time 1/23/2015 11:53am
JIM77 wrote:
Yes that will work, you need to use a Yzf banjo bolt though, at the caliper to clear the swing arm.
I've looked all over this thread for the brake upgrade and couldn't find it anywhere.

I thought I had what I needed but something's not right. I've got a '99 rotor, '97 carrier, turned my bolt head down on a grinder but that's not the problem, the bend in the fitting from the brake line to the caliper is the problem, it's angled wrong and hits the swingarm, nothing to do with the banjo bolt.

Are you supposed to bend the end fitting on the line?

Thanks in advance.
JohnnyOfast
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JohnnyOfast 1/23/2015 11:56am
1/23/2015 11:56am
JIM77 wrote:
Yes that will work, you need to use a Yzf banjo bolt though, at the caliper to clear the swing arm.
JohnnyOfast wrote:
I've looked all over this thread for the brake upgrade and couldn't find it anywhere. I thought I had what I needed but something's not right...
I've looked all over this thread for the brake upgrade and couldn't find it anywhere.

I thought I had what I needed but something's not right. I've got a '99 rotor, '97 carrier, turned my bolt head down on a grinder but that's not the problem, the bend in the fitting from the brake line to the caliper is the problem, it's angled wrong and hits the swingarm, nothing to do with the banjo bolt.

Are you supposed to bend the end fitting on the line?

Thanks in advance.
No sooner did I post my question I realized my problem. I used the rear brake line from a '92 and it does have a different bend on the end by the caliper, I do have a '96 line so I should be good to go, thanks anyways. once again, great thread.
david.murello 1/23/2015 2:59pm
1/23/2015 2:59pm
Thank you for the important information. I have a new question and wanting to build parts with other bike I would like to know what carburetor is alternative to PJ28K A that is rarely and at high price
barkhard696
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barkhard696 1/29/2015 12:09pm
1/29/2015 12:09pm
NOS McGrath parts for sale on eBay:

NOS Honda 1996 96 CR125 CR250 Right & Left Radiator Shrouds

181653317796

NOS 1996 1997 Honda CR125 CR250 WHITE Rear Fender

81653397380


NOS 1996 1997 Honda CR125 CR250 Seat 1996 McGrath Replica

181653402211

JIM77
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JIM77 1/30/2015 2:02am
1/30/2015 2:02am
Does anyone know of an option for the 96 NLA rear axle blocks.

I can't seem to find any aftermarket options and am thinking I might need to have a set machined. Or hunt for a 2nd hand set.

Do any other years fit? The parts fiche doesn't seem to think so.
JohnnyOfast
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JohnnyOfast 1/30/2015 9:46am
1/30/2015 9:46am Edited Date/Time 1/30/2015 9:51am
JIM77 wrote:
Does anyone know of an option for the 96 NLA rear axle blocks. I can't seem to find any aftermarket options and am thinking I might...
Does anyone know of an option for the 96 NLA rear axle blocks.

I can't seem to find any aftermarket options and am thinking I might need to have a set machined. Or hunt for a 2nd hand set.

Do any other years fit? The parts fiche doesn't seem to think so.
'95 & '96 have the bigger axle blocks, I had some machined already and have some extras, are you USA? Doh, see you're AUS, think the shipping would kill it.
JIM77
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JIM77 1/30/2015 1:22pm
1/30/2015 1:22pm
JIM77 wrote:
Does anyone know of an option for the 96 NLA rear axle blocks. I can't seem to find any aftermarket options and am thinking I might...
Does anyone know of an option for the 96 NLA rear axle blocks.

I can't seem to find any aftermarket options and am thinking I might need to have a set machined. Or hunt for a 2nd hand set.

Do any other years fit? The parts fiche doesn't seem to think so.
JohnnyOfast wrote:
'95 & '96 have the bigger axle blocks, I had some machined already and have some extras, are you USA? Doh, see you're AUS, think the...
'95 & '96 have the bigger axle blocks, I had some machined already and have some extras, are you USA? Doh, see you're AUS, think the shipping would kill it.
Thanks for the offer, your right freight would be a killer. With the 95 and 96 being the only ones compatible, even finding a decent used set would be a struggle.

I think I'll just have to get some machined and do what you've done, with a few extras.

If you get the chance could you post a photo of the finished product please?

Thanks James
JohnnyOfast
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JohnnyOfast 1/30/2015 3:48pm
1/30/2015 3:48pm
JIM77 wrote:
Does anyone know of an option for the 96 NLA rear axle blocks. I can't seem to find any aftermarket options and am thinking I might...
Does anyone know of an option for the 96 NLA rear axle blocks.

I can't seem to find any aftermarket options and am thinking I might need to have a set machined. Or hunt for a 2nd hand set.

Do any other years fit? The parts fiche doesn't seem to think so.
JohnnyOfast wrote:
'95 & '96 have the bigger axle blocks, I had some machined already and have some extras, are you USA? Doh, see you're AUS, think the...
'95 & '96 have the bigger axle blocks, I had some machined already and have some extras, are you USA? Doh, see you're AUS, think the shipping would kill it.
JIM77 wrote:
Thanks for the offer, your right freight would be a killer. With the 95 and 96 being the only ones compatible, even finding a decent used...
Thanks for the offer, your right freight would be a killer. With the 95 and 96 being the only ones compatible, even finding a decent used set would be a struggle.

I think I'll just have to get some machined and do what you've done, with a few extras.

If you get the chance could you post a photo of the finished product please?

Thanks James
I only had the '92 ones to work off of, if I was to do it again I would tighten a few things up, even the stock honda block leaves space were the axle head can turn, would be better if it was flush. Also the adjuster bolt only hits about 1/2 it's face on the block, stock is only a hair more,,,, I would make the front face a few millimeters wider so the whole adjust head hits it. I can take some better pictures later. Would also make the flat against the S/A a little wider too, but these will work.



JIM77
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JIM77 1/31/2015 2:53am
1/31/2015 2:53am
Thanks mate, just the sort of feedback I've been looking for. I only have one stock one to copy and I think I will tighten up the tolerance like you suggest.
JohnnyOfast
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JohnnyOfast 1/31/2015 8:46am
1/31/2015 8:46am
I'll save you some work, he did mine off my cave man drawing no reason you can't, I marked the mods I would do. Also I forgot to note it but the .468 dimension should be kicked up about 4 mm so the whole adjuster bolt hits.



In this picture you can see the stock '92 on the right, custom and stock '96 axle blocks.













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