Canadian 1988 Honda CR250 restos. Bike #1 Complete

crobargreg
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crobargreg 7/7/2017 1:57pm
7/7/2017 1:57pm
Bikes coming along nice. Cant wait to see it finished
avmechanic
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avmechanic 7/8/2017 11:23pm
7/8/2017 11:23pm
crobargreg wrote:
Bikes coming along nice. Cant wait to see it finished
I have most all the parts I need. I just need to get busy assembling the bike. Hopefully I will make some noise near the end of summer.
avmechanic
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avmechanic 7/8/2017 11:28pm
7/8/2017 11:28pm
OK. I moved all my pictures to a new site and made new links for pictures to all my earlier posts. What a pain in the ass. Photobucket Sucks ass for fucking us over.

On a lighter note. While trying to find all my pictures I found two old pictures of my original 1988 Cr250 taken in about 1990 or so. Hopefully this bike will have some of the magic the old one had.




Greg
avmechanic
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avmechanic 11/15/2017 8:38pm
11/15/2017 8:38pm Edited Date/Time 11/25/2017 10:14am






It has sure been tough to make progress. I managed to find 1 afternoon recently so I started to assemble my pieces to the bike. I have pretty much all parts and sub assemblies ready. Just need to assemble and fire this bad boy up. I installed the All Balls conversion bearings on the 2001 Honda triple clamps and fit the forks to this bike. The stem is longer so I had to use the thick washer that comes with the conversion both under the bottom bearing and on top. The 2001 47mm Showa fork is quite long so I had to slide them up the clamps a long way so that the measurement to the axle from the reference mark I had on the steering stem of the frame had similar dimensions to the original 43mm conventionals. I will ride it to see if I need to do anything different as far as where the forks should sit in the clamps. I have some 1 1/8" fat bar mounts that are offset so I offset the bar forward. I like the riding position. I like my bars high and forward. Riding position feels modern and a lot like my KTM with the Yamaha YZ footpegs I am using. I have mounted the rear suspension along with the wheels, subframe and airbox. It should start coming together quickly now. Hopefully I can find a day or two here in the next few weeks.
Greg.

The Shop

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avmechanic
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avmechanic 2/4/2018 4:03pm
2/4/2018 4:03pm






I fit in another couple afternoons of work. I installed the footpegs for good. I had to drill the mounts and the footpegs to 7/16" and use some 7/16" clevis pins. The correct 10mm pins were super sloppy in the mounts because the previous owner never welded the holes up before powered coating. This kind of frame prep came up to haunt me in a couple other spots too. The 7/16" pins tighten everything up nicely. Otherwise the YZ pegs would have fit with no modification. I mounted up the rear fender but fount that the threads for the rear most fender mounts were stripped out on one side and had a broken bolt in the other. Again this is something I would have repaired before powder coating. At least I don't see any bad weld repairs or cracks anywhere. I also pulled the airbag off and resealed the boot to the box. I had a set of Honda OEM grips kicking around so I mounted them up. I mounted up the rear master cylinder and hope to get the brakes together and bled next work session. Not the assembly rate I wanted but any time I can find for progress is good. Hopefully I can smell some premix by spring.
Greg
LOVEMYCR500
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LOVEMYCR500 2/5/2018 11:42am
2/5/2018 11:42am
Can you tell me where you got that rear brake lever rip please. Looks of pretty good fit and quality I am looking for something just like that for the CR 500 I'm rebuilding
avmechanic
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avmechanic 2/5/2018 11:53am
2/5/2018 11:53am
LOVEMYCR500 wrote:
Can you tell me where you got that rear brake lever rip please. Looks of pretty good fit and quality I am looking for something just...
Can you tell me where you got that rear brake lever rip please. Looks of pretty good fit and quality I am looking for something just like that for the CR 500 I'm rebuilding
I picked it up on Aliexpress https://www.aliexpress.com/item/CNC-Aluminum-Brake-Pedal-Tip-for-SDG-SS… It works good and was cheap.
Greg
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LOVEMYCR500 2/5/2018 12:28pm
2/5/2018 12:28pm
Okay cool I will check it out that is cheap
sandman768
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sandman768 2/5/2018 1:30pm
2/5/2018 1:30pm
Some really nice work your doing here....
avmechanic
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avmechanic 2/8/2018 2:09pm
2/8/2018 2:09pm
sandman768 wrote:
Some really nice work your doing here....
Thanks.
Pirate421
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Pirate421 2/8/2018 5:00pm
2/8/2018 5:00pm
Looks good! I ordered a new ufo fender for my 89 a few days ago, it came in today and it’s pink! Says on the ufo packaging it’s for an 87-99 but it’s definitely about three shades too light. Yours does t look bad
avmechanic
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avmechanic 2/8/2018 5:45pm
2/8/2018 5:45pm
Pirate421 wrote:
Looks good! I ordered a new ufo fender for my 89 a few days ago, it came in today and it’s pink! Says on the ufo...
Looks good! I ordered a new ufo fender for my 89 a few days ago, it came in today and it’s pink! Says on the ufo packaging it’s for an 87-99 but it’s definitely about three shades too light. Yours does t look bad
I am really pleased with my UFO plastic. It seems as nice as the Honda stuff for finish. The fitment seems good so far. My colour seems to match great. I kind of wish the fender had been fully drilled as I had a hard time marking the holes and trying to get it to sit right. If your colour is not correct I would confirm the part number and consider calling UFO/Tuff racing to get it corrected.
Greg
avmechanic
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avmechanic 3/17/2018 12:15pm
3/17/2018 12:15pm
Finally a new update. I have been picking away a couple hours a day this week that I have had off. I have installed the front and rear brakes, ignition system and wiring, the radiators and hoses, new clutch and throttle cables, handlebar controls and hand guards. I checked the ignition and it seems to have a nice strong spark. I then cleaned up one of my carbs up and installed it along with an old set of V Force delta reeds. I have one set of V force reeds and two Boyesen Rad Valves. I think the Rad Valve is a better product so I want to save them for my other projects. I have some new Boyesen duel stage reeds I could install on a stock reed cage too if I want. Once the bike is running I may do some swapping to compare though. It seems to be a slow process with little stumbling blocks all along the way. I found that the clamp on the frame that holds the rear brake reservoir hose away from the exhaust was missing. Too bad it wasn't repaired before powder coating. I ended up grinding the rest of the clamp and weld off the frame then drilling and tapping the frame for a stud that I can attach a clump to the frame to hold the hose away from the exhaust. I still need to add fluid and bleed brakes. I will need to add coolant. Going to go with Evens coolant as this one still has a magnesium pump in it. I am happy to see some progress and it is turning to spring here so it is time to get it done.
Greg








avmechanic
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avmechanic 3/17/2018 12:36pm
3/17/2018 12:36pm


I had to see what it would look like with the plastic. I think it will end up looking pretty awesome. I am looking forward to the final pieces and decals.

Greg

Pirate421
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Pirate421 3/17/2018 9:00pm
3/17/2018 9:00pm
Awesome progress Greg can’t wait to see it finished! I tried a set of 2015 yz450 pegs, and while they fit good, I had a problem with the kickstart lever catching the peg. I could kick the bike down fine but it would hang up on the return stroke. I ended up putting the stock pegs back on for now and will see if I can grind the peg to make it work
avmechanic
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avmechanic 3/18/2018 12:29pm
3/18/2018 12:29pm
Pirate421 wrote:
Awesome progress Greg can’t wait to see it finished! I tried a set of 2015 yz450 pegs, and while they fit good, I had a problem...
Awesome progress Greg can’t wait to see it finished! I tried a set of 2015 yz450 pegs, and while they fit good, I had a problem with the kickstart lever catching the peg. I could kick the bike down fine but it would hang up on the return stroke. I ended up putting the stock pegs back on for now and will see if I can grind the peg to make it work
Thanks. I will have to double check the kicker for interference to the peg. These are 2002 pegs. I have run the kicker through a number of times and didn't see any issues but I will look closer to be sure.
Pirate421
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Pirate421 3/18/2018 1:02pm
3/18/2018 1:02pm
avmechanic wrote:
Thanks. I will have to double check the kicker for interference to the peg. These are 2002 pegs. I have run the kicker through a number...
Thanks. I will have to double check the kicker for interference to the peg. These are 2002 pegs. I have run the kicker through a number of times and didn't see any issues but I will look closer to be sure.
Yea mine are 2015. My kicker seemed fine running it through slowly but once it was a swift kick to get it fired it stuck every time
avmechanic
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avmechanic 3/18/2018 1:13pm
3/18/2018 1:13pm Edited Date/Time 3/18/2018 1:16pm
I was wanting to install a flywheel weight on my bike as I had used one back in the day on my original 88 CR250. It worked fantastic and made that bike hook up amazing. Steahly has discontinued the flywheel for the 86' to 88' and now only carries a 90' to 2001 model. I spotted a PN 506H model for the 90' to 2001 CR250 on ebay for $25 and it looked similar to the one I had and after comparing the look of the flywheel for the 90' to 2001 it seemed like I might be able to make it work. I installed it yesterday and the locking set screws would not reach the spot they are supposed to press against. I took the set screws out and drilled/tapped new locations in the face of the flywheel weight to lock it to the front face of my flywheel. It seems pretty darn secure so hoping it will work fine. I have pictures of the flywheel but forgot to take any of the modifications or of it installed. These bikes really benefit from the weight so I am glad to have a solution. If this doesn't work I will machine up one myself on my father in laws lathe.
Greg




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avmechanic
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avmechanic 4/21/2018 8:14pm
4/21/2018 8:14pm
The bike has pretty much come together. I just need to add fluids and bleed the brakes. Some final touches will be the decals. Some of the things I finished up with were the chain and chain rollers. Carb kit and carb install along with a V force reed. One of the polished tanks I have along with new rad scoops. I found that the hole for the lower rad scoops did not line up well with the hole it attached to on the aftermarket rads. The rads did fit well otherwise. I mounted up the pipe. I had to do a little tweak on the inlet as it did not line up well to the exhaust flange. The pipe was in really good shape with just a couple dings in it so I just sand blasted it and gave it a coat of high temp black. I have another OEM pipe that needs some dents fixed and an FMF gnarly as well. For the muffler I managed to save two OEM mufflers. One the aluminum was dented pretty good but with some body hammer work I managed to straighten it out. The core was broken so I blasted it and welded it back together. I did a fresh repack and put it together. It turned out nice. I am still working on another that should work out as nice or nicer. I am really pleased with how it is all coming together. I finally took it out of my little shop and have it out in the daylight. I loaded it up and brought it out with me to my summer forest firefighting job on the firebase. I hope to finish it up in the next week or so then fire it up and get the jetting dialled in. I went with the recommendations from Eric Gore's book with the Honda 1369 needle 55 pilot and 175 main. I will run 40:1 mix for the gas which is what his jetting recommendation suggested. This bike is going to be sweet.
Greg


avmechanic
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avmechanic 4/29/2018 10:30pm
4/29/2018 10:30pm
Well. It is together. It has been about 2 years. I finished up a lot of odds and ends over the last week. I bled the brakes, installed a skid plate, a rotor guards. When I filled the cooling system I found coolant was leaking from the water pump. I ended up having to pull the water pump cover and reseal it with new gaskets and a light layer of silicone. No leaks now from the cover. I am running Evens coolant as this is still a Magnesium water pump. Last was installing decals. I think it looks great. Finally I poured some gas in it this afternoon. It was a bitch to start. I kicked it over till I got tired. I tried another plug and then in the end I finally bump started it. Once running it has started easily. It runs really good. I went with Eric Gore's recommended jetting from his book. 55 Pilot jet with 175 Main along with a 1369 needle and 40:1 fuel mix with the original Keihin PJ carb. I might need to do some fine jetting but overall it seems to run great. I rode it around a little then let it cool. I ended up firing it up again about an hour later and went for a 10 or 15 min ride in the woods. It seems to run great and the suspension feels real good as it is. It will need some work yet. One issue I am having is that often the kicker does not engage when I kick it. I have plenty of spare parts so I will pull the clutch case again and swap some of the parts out. The front brake is still mushy so I might have to do some more bleeding there. I am going to try and do a photo shoot before I go and get it real dirty. The picture I have attached is in my crew house kitchen. It was cold and rainy out so I brought it into my crew house at work to finish up the decals. My wife would not be so understanding. I am pleased with how it turned out.
crobargreg
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crobargreg 5/1/2018 6:00pm
5/1/2018 6:00pm Edited Date/Time 5/1/2018 6:02pm
avmechanic wrote:
The bike has pretty much come together. I just need to add fluids and bleed the brakes. Some final touches will be the decals. Some of...
The bike has pretty much come together. I just need to add fluids and bleed the brakes. Some final touches will be the decals. Some of the things I finished up with were the chain and chain rollers. Carb kit and carb install along with a V force reed. One of the polished tanks I have along with new rad scoops. I found that the hole for the lower rad scoops did not line up well with the hole it attached to on the aftermarket rads. The rads did fit well otherwise. I mounted up the pipe. I had to do a little tweak on the inlet as it did not line up well to the exhaust flange. The pipe was in really good shape with just a couple dings in it so I just sand blasted it and gave it a coat of high temp black. I have another OEM pipe that needs some dents fixed and an FMF gnarly as well. For the muffler I managed to save two OEM mufflers. One the aluminum was dented pretty good but with some body hammer work I managed to straighten it out. The core was broken so I blasted it and welded it back together. I did a fresh repack and put it together. It turned out nice. I am still working on another that should work out as nice or nicer. I am really pleased with how it is all coming together. I finally took it out of my little shop and have it out in the daylight. I loaded it up and brought it out with me to my summer forest firefighting job on the firebase. I hope to finish it up in the next week or so then fire it up and get the jetting dialled in. I went with the recommendations from Eric Gore's book with the Honda 1369 needle 55 pilot and 175 main. I will run 40:1 mix for the gas which is what his jetting recommendation suggested. This bike is going to be sweet.
Greg


Bike looks great. Makes me want to refresh my 88 cr250r.
avmechanic
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avmechanic 5/2/2018 9:22am
5/2/2018 9:22am Edited Date/Time 5/2/2018 9:34am
I went for another short ride and I have to say I am super impressed with this bike. Even though it was over 20 years ago that my last 88' got stolen I found this bike felt so natural that it was like I just rode it yesterday. It has good torquey power with a nice spread of RPM. The suspension feels good and it handles well. I am sure it is not near as powerful as a new YZ250 or KTM/Husky 250 but it has some bark and I could probably still be competitive in a vet off-road class. The gearing is a bit high for many of the tight trails I ride so I may have to gear it down a little. I have some other sprockets so I may do just that. I actually don't remember the gearing I installed. Probably stock gearing. I left the bike at work and have now gone home for a couple weeks off. I am going to bring some parts back with me and sort out the kickstarter and work on getting the brakes bled a little better. Maybe a little suspension adjustment and possibly a little jetting adjustment and it should be good to go. It will be time to get started on the next one. I will start with blasting the next frame and doing some frame repairs. I will keep posting the finish on this one and progress on the next.
Greg
Bent206
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Bent206 5/4/2018 6:10am
5/4/2018 6:10am
Great build!! That is a nice looking bike.
I love seeing these old bikes brought back to life......especially to this level.
ChasedMoto
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ChasedMoto 5/30/2018 2:45pm
5/30/2018 2:45pm Edited Date/Time 5/30/2018 2:48pm
avmechanic wrote:
[img]https://p.vitalmx.com/photos/forums/2017/11/15/225263/s1200_IMG_4098.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2017/11/15/225265/s1200_IMG_4101.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2017/11/15/225268/s1200_IMG_4100.jpg[/img] It has sure been tough to make progress. I managed to find 1 afternoon recently so I started to assemble my pieces to...






It has sure been tough to make progress. I managed to find 1 afternoon recently so I started to assemble my pieces to the bike. I have pretty much all parts and sub assemblies ready. Just need to assemble and fire this bad boy up. I installed the All Balls conversion bearings on the 2001 Honda triple clamps and fit the forks to this bike. The stem is longer so I had to use the thick washer that comes with the conversion both under the bottom bearing and on top. The 2001 47mm Showa fork is quite long so I had to slide them up the clamps a long way so that the measurement to the axle from the reference mark I had on the steering stem of the frame had similar dimensions to the original 43mm conventionals. I will ride it to see if I need to do anything different as far as where the forks should sit in the clamps. I have some 1 1/8" fat bar mounts that are offset so I offset the bar forward. I like the riding position. I like my bars high and forward. Riding position feels modern and a lot like my KTM with the Yamaha YZ footpegs I am using. I have mounted the rear suspension along with the wheels, subframe and airbox. It should start coming together quickly now. Hopefully I can find a day or two here in the next few weeks.
Greg.
Hi all,

Just wondering about the comparability of triple clamps on the 1988 cr250.
Just began a rebuild on my dads stolen bike we recently got back, and the front forks were ridden without fork oil for who knows how long and are shot.
Does anyone know which front ends fit on the frame. Or just which triple clamps will work?

Thanks. And avmechanic, nice bike. Im planning on doing something similar.

Also, with the 2001 triples, what conversion bearings did you use?
crobargreg
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crobargreg 5/30/2018 2:51pm
5/30/2018 2:51pm
avmechanic wrote:
[img]https://p.vitalmx.com/photos/forums/2017/11/15/225263/s1200_IMG_4098.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2017/11/15/225265/s1200_IMG_4101.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2017/11/15/225268/s1200_IMG_4100.jpg[/img] It has sure been tough to make progress. I managed to find 1 afternoon recently so I started to assemble my pieces to...






It has sure been tough to make progress. I managed to find 1 afternoon recently so I started to assemble my pieces to the bike. I have pretty much all parts and sub assemblies ready. Just need to assemble and fire this bad boy up. I installed the All Balls conversion bearings on the 2001 Honda triple clamps and fit the forks to this bike. The stem is longer so I had to use the thick washer that comes with the conversion both under the bottom bearing and on top. The 2001 47mm Showa fork is quite long so I had to slide them up the clamps a long way so that the measurement to the axle from the reference mark I had on the steering stem of the frame had similar dimensions to the original 43mm conventionals. I will ride it to see if I need to do anything different as far as where the forks should sit in the clamps. I have some 1 1/8" fat bar mounts that are offset so I offset the bar forward. I like the riding position. I like my bars high and forward. Riding position feels modern and a lot like my KTM with the Yamaha YZ footpegs I am using. I have mounted the rear suspension along with the wheels, subframe and airbox. It should start coming together quickly now. Hopefully I can find a day or two here in the next few weeks.
Greg.
ChasedMoto wrote:
Hi all, Just wondering about the comparability of triple clamps on the 1988 cr250. Just began a rebuild on my dads stolen bike we recently got...
Hi all,

Just wondering about the comparability of triple clamps on the 1988 cr250.
Just began a rebuild on my dads stolen bike we recently got back, and the front forks were ridden without fork oil for who knows how long and are shot.
Does anyone know which front ends fit on the frame. Or just which triple clamps will work?

Thanks. And avmechanic, nice bike. Im planning on doing something similar.

Also, with the 2001 triples, what conversion bearings did you use?
I have an 1988 cr250r im running 1989 triple clamps and 1991 forks inside the clamps. Went from convensional to upside down. You usually need the correct axle and spacers for the year fork your runing. Im sure you can go up to 1993 on the forks. The wheel is the same.
crobargreg
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crobargreg 5/30/2018 2:54pm
5/30/2018 2:54pm
avmechanic wrote:
[img]https://p.vitalmx.com/photos/forums/2017/11/15/225263/s1200_IMG_4098.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2017/11/15/225265/s1200_IMG_4101.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2017/11/15/225268/s1200_IMG_4100.jpg[/img] It has sure been tough to make progress. I managed to find 1 afternoon recently so I started to assemble my pieces to...






It has sure been tough to make progress. I managed to find 1 afternoon recently so I started to assemble my pieces to the bike. I have pretty much all parts and sub assemblies ready. Just need to assemble and fire this bad boy up. I installed the All Balls conversion bearings on the 2001 Honda triple clamps and fit the forks to this bike. The stem is longer so I had to use the thick washer that comes with the conversion both under the bottom bearing and on top. The 2001 47mm Showa fork is quite long so I had to slide them up the clamps a long way so that the measurement to the axle from the reference mark I had on the steering stem of the frame had similar dimensions to the original 43mm conventionals. I will ride it to see if I need to do anything different as far as where the forks should sit in the clamps. I have some 1 1/8" fat bar mounts that are offset so I offset the bar forward. I like the riding position. I like my bars high and forward. Riding position feels modern and a lot like my KTM with the Yamaha YZ footpegs I am using. I have mounted the rear suspension along with the wheels, subframe and airbox. It should start coming together quickly now. Hopefully I can find a day or two here in the next few weeks.
Greg.
ChasedMoto wrote:
Hi all, Just wondering about the comparability of triple clamps on the 1988 cr250. Just began a rebuild on my dads stolen bike we recently got...
Hi all,

Just wondering about the comparability of triple clamps on the 1988 cr250.
Just began a rebuild on my dads stolen bike we recently got back, and the front forks were ridden without fork oil for who knows how long and are shot.
Does anyone know which front ends fit on the frame. Or just which triple clamps will work?

Thanks. And avmechanic, nice bike. Im planning on doing something similar.

Also, with the 2001 triples, what conversion bearings did you use?
Now if you want to stay with the 88 clamps and conventional fork i would go with a set of 1987 forks. They are valved better and slide right in.
avmechanic
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avmechanic 5/30/2018 5:20pm
5/30/2018 5:20pm
You can fit all kinds of clamps/forks if you want. Check out ALL Balls. https://www.allballsracing.com/index.php/forkconversion If you want to stick with the conventionals XR650L forks fit your clamps and are very similar to the 87/88 forks. They are readily available for reasonable prices. I have some 97' RM250 49mm conventional Showa forks to use on my next bike. They are supposed to be awesome forks and really reasonably priced as well. I also have some 2011 RMZ forks to use for when I build my 1990 that I have in boxes. All kind of options. Most fork conversions will require the clamps, front axle and wheel hub from the donor bike. Good luck on your build and show us your progress in a post.
Greg
TooOld4WFO
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TooOld4WFO 5/31/2018 10:09am
5/31/2018 10:09am
Incredible looking Honda. I honestly feel it rivals anything you can buy today for sheer appearance.
Great write up and thank you for covering details about mods and parts. It that kind of information which helps others doing full restores.
I’m gathering up parts to do my own on a 95 250 Honda.
I will now be doing the research on that flywheel mod.
I was going to just leave my rims unpainted but love the black look too much.

Outstanding job and thanks for the inspiration.
avmechanic
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avmechanic 5/31/2018 1:00pm
5/31/2018 1:00pm
TooOld4WFO wrote:
Incredible looking Honda. I honestly feel it rivals anything you can buy today for sheer appearance. Great write up and thank you for covering details about...
Incredible looking Honda. I honestly feel it rivals anything you can buy today for sheer appearance.
Great write up and thank you for covering details about mods and parts. It that kind of information which helps others doing full restores.
I’m gathering up parts to do my own on a 95 250 Honda.
I will now be doing the research on that flywheel mod.
I was going to just leave my rims unpainted but love the black look too much.

Outstanding job and thanks for the inspiration.
Glad you enjoyed the build. I like to share the info for others. It is often a lot of research to figure out some of this stuff so it is good to save someone else the trouble. I agree on the look of the bike. I think it rivals the new stuff too. When you build your bike please share the build. I always enjoy reading about how others have done it too.
Greg
EL Sammo
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EL Sammo 6/1/2018 5:07am
6/1/2018 5:07am
Excellent! Good work getting it sorted.

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