Honda XR250R build e-start- titanium

Was able to find an alloy top nut for the steering stem. Should save a gram or two over the Ti one.

Small preview of the Ti- Exhaust.

Axles are getting there

Progress is slow at the moment, waiting on parts. Got the alloy top stem nut. It ended saving another 5g.

I was able to find a nos Hinson Clutch basket, I had already given up on finding one as these were discontinued in 2005.

So after some time, nearly all the parts have arrived. I’m still missing the rims. In the next couple of days I‘m going to be starting on the engine. The Ti-axles arrived from the UK too. And another 250g is savings.

A couple of days ago a was able to accumulate another Wr250f, which happened to have YZ250F suspension and a Yz front wheel. I‘ll check one of these days if Yz wheel has any advantages in weight over the WR250F wheel.







Total: -5,805g

Yeah it’s pretty sweet, and the best thing about is that you easily save another 2-3 kg with going to different rims, fat bike tubes. At the end it’s all the Little Details that add up. Even a big bore can add to the savings if the cylinder sleeve is steel. Should be a bit better power to weight ratio als well.

So finally the camshaft came. I‘ll start dissembling the top end next.

here the cam After DLC coating 

Left the MD30 cam sprocket, right XR250R cam sprocket 40g difference. So another 40gs in savings.


Total:-5,845g

I get the weight of the jug when it’s cleaned up an post it here, as I guess there’s a couple grams the I’ll be able to save with a 5mm overbore in the Steel liner.

Here’s the weight of the cylinder before the big bore.

So since I stuck at them moment do to the dumb corona regulations in Germany. I got some time use the kitchen scale and verify some things. So the hotcam saved 69gs as it doesn’t use the auto decomposition unit.



The cool thing I found out a while ago is that the WR250F starter motor will fit the XR250 MD30. There is just a small alloy bracket that has to be made to maintain the ground wire connection.
Here the savings are 654g.




Which gives us a total of roughly 6,568kg that have been saved so far. And there is more to come.

we will be making a run of these if anyone is interested just contact me they will be sold a 380 USD shipped a piece

Titanium header for the XR250R

Head is ready to get some light porting done. I was not surprised to see the springs, valves and everything else still is spec. 1995-2021😊. If only the Titanium valves on my bike would last as long.

I just got the rear fat bike tube that I’m going to try using. I going to stick to the oem rear rim, till now I’ve not been able to source a rear Excel.

The OEM tube weighs 620g, The Maxxis Fattube ist supposed to be around 450g but I can't find any available here at the Moment. There's another Schwalbe tube that only weighs about 200g. I will be testing that one for the front.
it would so cool if that works out then I'll be over 7kgs creeping towards 8kgs in savings. The Exhaust is on its way from Japan to Germany. I'm really excited to see what the savings with that will be.

Still on the list to save a couple grams:

-Excel front an Rear rim, check if the Yamaha or KX Alloy spoke nipples fit the rear XR Spokes
-Motostuff front Brake Rotor stock size that will fit 2003-2013 YZF Rim ( does anyone have a spare one?)
-Carbon tankmounts and Airboot support need to be made.
-Starter motor support bracket
- replace the

As usually things go wrong... the Chinese send me a Wonderfull exhaust system. There’s only one issue. The header pipe is not titanium. It’s nice good workmanship. 2mm bigger inner diameter. But just no ti.

After a little frustration, I compared the weights of the two systems, If I would run the system Webike send me I would only be saving 50g to my current setup. Where as with the titanium header it should be at least 700g. Well we will see, at the moment I’ll really thinking that these Webike people are nowhere near interested in sorting this out.

So got the cylinder back from the machinist. 352g lighter that before.
Comparing the weights of two pistons. Results i a total loss of 312g. We are at a total of 6,88kg

It’s my wife’s bike, she likes it but has some difficulties with the weight. I’m trying to make riding more enjoyable for her. That’s actually the reason for this build. Making her more comfortable with bike makes riding it a lot more fun and helps her develop her riding style as she gains confidence.

Small progress. Hinson basket is ready to go.

Slow progress... but it’s getting there.