Another build! 1995 CR250

Anaxdlere
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Anaxdlere
Edited Date/Time 10/30/2017 12:15pm
After bringing the 92 CR250 back to life (and then bringing a 1996 back to life too), I have now found myself addicted to finding these things that are doomed or unwanted and resurrecting them. This one is in FAR better shape than the others I have done (well, other than the motor). The plan at this point is to do a light redo and make it a rider, but things with me never go to plan. The piston is frozen solid in the cylinder, so will try the 2001 cylinder conversion on this to do something different. I will post some pics along the way.



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sands-cr250
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sands-cr250 9/26/2016 2:05pm
9/26/2016 2:05pm
Awesome!

I bought another CR this year as well, a 2001'

I still really dig my 92' though, it seems to be more violent on the power delivery compared to the 2001', I think that's why I like it more.

I see you are in STL! Me too, well...I work there, live on IL side. I've got some parts here and there. Let me know if you are looking for something. I might have it.

-sands
VintageRacer
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VintageRacer 9/26/2016 9:37pm
9/26/2016 9:37pm
Roller looks solid, should be easy to bring back to life.
Anaxdlere
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Anaxdlere 9/27/2016 6:11am
9/27/2016 6:11am
The engine is where I will have some work to do. Piston is seized in the cylinder and it looks like it has rusted or who knows what! I suppose I will have to split the case to get it removed (which I was going to do anyway to redo the bottom end).





Anaxdlere
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Anaxdlere 9/29/2016 6:44am
9/29/2016 6:44am
The OEM cylinder is toast. I am going to order a 2001 cylinder,piston and head since I can still get them. I was asked a good question, do I use the 95 power valves or do I also need to get the 2001 power valves? I am hoping that I can just take out the existing power valves and put them in the new cylinder, use the new piston and head and bolt everything right up.
Has anyone here already done this "conversion"?

The Shop

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mxracer618 9/29/2016 7:58am
9/29/2016 7:58am
Anaxdlere wrote:
The OEM cylinder is toast. I am going to order a 2001 cylinder,piston and head since I can still get them. I was asked a good...
The OEM cylinder is toast. I am going to order a 2001 cylinder,piston and head since I can still get them. I was asked a good question, do I use the 95 power valves or do I also need to get the 2001 power valves? I am hoping that I can just take out the existing power valves and put them in the new cylinder, use the new piston and head and bolt everything right up.
Has anyone here already done this "conversion"?
I know the main valve flap and the two sub valves are unique to the 00-01 CR's, but most of the rest of the parts are the same from 92-01. I spot checked some of the part numbers and the main flap seems to have changed about every year, and the sub valves are all over the place. I suspect, but am not 100% sure, that the various different year flaps & Sub valves will all mount up in the same cylinder. you'd have to get several of them side by side to figure out what is different about them.

I would also bet that somewhere in all those different flaps is one that works a little better than the others. I can think of two guys who might know more about that, Joe Shedron, who is now a mechanic at G-force Powersports in Denver, but used to do all the engine work for Moose Racing, and also did a lot with Steve Hatch and the Factory Suzuki Enduro team in the 90's and Larry Leavitt, who owns LSE Racing, and is an absolute guru on all things horsepower. Those guys are my Go-to when i'm stumped.. ..... hope this helps!
Anaxdlere
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Anaxdlere 9/30/2016 10:21am
9/30/2016 10:21am
Thanks for all the info! I will reach out to those guys and see what I can find out.
I usually use the OEM-CYCLE site to help me figure out part compatibility between years, but didn't find much about the power valves on it.
Anaxdlere
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Anaxdlere 10/6/2016 8:50pm
10/6/2016 8:50pm
I was able to remove the cylinder with the frozen piston inside. That was a MFer! At first glance at the bottom end, there is a spot I don't recognize that I am wondering if is where something exploded inside. Does this hole look like it is normal??





Anaxdlere
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Anaxdlere 10/7/2016 6:47am
10/7/2016 6:47am
Found an image of another 95 crankcase and it looks like that should just be more of a "bump" instead of a hole that it is now. I assume the break and hole that is there now is no bueno, so time to hunt for a right inner crankcase.

Rockinar
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Rockinar 10/8/2016 8:21pm
10/8/2016 8:21pm

That should be a bump end for the tip of a case bolt. Looks like they grinded it down or something. People do strange things to bikes. I wonder if a normal bolt would still fit in it if you got it welded. Not sure how clean of a weld you could get on it with all the carbon on it.



moore433
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moore433 10/8/2016 10:26pm
10/8/2016 10:26pm
Looks like you found why it was rusted inside. Water leaking through the case there...
zer0signal 10/27/2016 6:54pm
10/27/2016 6:54pm
Rockinar wrote:
That should be a bump end for the tip of a case bolt. Looks like they grinded it down or something. People do strange things to...

That should be a bump end for the tip of a case bolt. Looks like they grinded it down or something. People do strange things to bikes. I wonder if a normal bolt would still fit in it if you got it welded. Not sure how clean of a weld you could get on it with all the carbon on it.



They put the wrong bolt in that was to long and HeManned it in. I bought a 2001 CR where a kid took the bolts out to paint the heads red and put bolts in the wrong holes and busted through the case.
Kidkawie
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Kidkawie 10/28/2016 4:36am
10/28/2016 4:36am
Nice save!

Id just get the case welded. Bust the piston apart with a BFH send the cyl out to Millenium.
Anaxdlere
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Anaxdlere 1/17/2017 7:37am
1/17/2017 7:37am
Frame all done. Rear shock rebuilt (had Pro Circuit internals, so that was a bonus). Got a replacement right inner and another 95 cylinder and and had that redone by Millenium (this one was just reamed after I got that cylinder out). Going to make this one a rider and will likely have some of the McGrath graphics on it since many folks around here are looking for that so will help with resale.
Vapor Blasting is the way to go on these cases! Wow! The shop that did it for me used it on display at the motorcycle show this past weekend to show off the results.









nine1seven
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nine1seven 1/17/2017 8:48am
1/17/2017 8:48am
I need to get on this vapor blasting bandwagon. Those cases look awesome! Do you mind sharing the contact info for the guys you used? I have done a little searching for a shop locally with no luck. Anyone know of vapor blasters around Houston, TX?

If you decide to do factory Honda graphics let me know I have the best ones. Nice job and thanks for sharing your project.

DJ
Anaxdlere
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Anaxdlere 1/17/2017 11:40am
1/17/2017 11:40am
nine1seven wrote:
I need to get on this vapor blasting bandwagon. Those cases look awesome! Do you mind sharing the contact info for the guys you used? I...
I need to get on this vapor blasting bandwagon. Those cases look awesome! Do you mind sharing the contact info for the guys you used? I have done a little searching for a shop locally with no luck. Anyone know of vapor blasters around Houston, TX?

If you decide to do factory Honda graphics let me know I have the best ones. Nice job and thanks for sharing your project.

DJ
I used a local shop (Cycle House Performance). They do all my powder coating too. Great place and I highly recommend them.
Anaxdlere
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Anaxdlere 1/24/2017 7:10pm
1/24/2017 7:10pm
Newly replated and vapor blasted cylinder. Those power valves look brand new! Sorry for the giant picture



Anaxdlere
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Anaxdlere 1/25/2017 6:35am
1/25/2017 6:35am
Frame and shock redone.




Anaxdlere
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Anaxdlere 8/14/2017 8:29am
8/14/2017 8:29am
Finally getting around to working on this again. Have too many projects going on, so had to hide this one in a closet while I build it Smile . 10 bikes is apparently considered excessive, according to the missus.


Pit Row

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EL Sammo
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EL Sammo 8/18/2017 2:10am
8/18/2017 2:10am
Looking good!
tempura
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tempura 8/19/2017 12:31am
8/19/2017 12:31am
I have a NOS, unopened Cycra works plate for that bike, if you are interested.




Anaxdlere
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Anaxdlere 8/22/2017 11:38am
8/22/2017 11:38am
Nice looking works plate! I might send you a message about picking it up.

The seat cover Throttle Jockey sent was cut a bit too short so waiting on a replacement. I know the AMA sticker is not the right one, but again, this is going to be a rider, so overlooking many small details.



tempura
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tempura 8/23/2017 6:39pm
8/23/2017 6:39pm
Let me know if you want it. It's been waiting years to be used.
Anaxdlere
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Anaxdlere 10/30/2017 6:31am
10/30/2017 6:31am
Took her for a spin this weekend. Have a few small kinks to work out but the motor and the handling are spectacular. So much fun!



MaxPower
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MaxPower 10/30/2017 6:57am
10/30/2017 6:57am
Anaxdlere wrote:
Finally getting around to working on this again. Have too many projects going on, so had to hide this one in a closet while I build...
Finally getting around to working on this again. Have too many projects going on, so had to hide this one in a closet while I build it Smile . 10 bikes is apparently considered excessive, according to the missus.


I call a wardrobe closet of 50 or more women's shoes excessive . Everyone has thongs that are important to them
look out below
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look out below 10/30/2017 12:15pm
10/30/2017 12:15pm
Anaxdlere wrote:
Finally getting around to working on this again. Have too many projects going on, so had to hide this one in a closet while I build...
Finally getting around to working on this again. Have too many projects going on, so had to hide this one in a closet while I build it Smile . 10 bikes is apparently considered excessive, according to the missus.


MaxPower wrote:
I call a wardrobe closet of 50 or more women's shoes excessive . Everyone has thongs that are important to them
That just made me think of something great!! Next time the wife says i have to sell a bike to get a new one (due to lack of space in the garage), i will tell her to get rid of her shoes because they all don't fit in the closet. Thanks fellas!!

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