1994 cr250. Uk rebuild

Stashed this away up in the roof of my garage over the past few months as I've been busy with other projects , added to the fact I found some hidden nasties when I stripped the engine (typical!)

Will divulge in another post when I get the pictures together. Pulled it all out this week, had a quick mock up today - bit of motivation!

Hopefully have it running for spring .

Time to get cracking!

Ignore the garage mess 😂🤦‍♂️

Few more bits for the last push to rebuild. 

I will update this with more pictures and a few of the hurdles I've had to overcome!

No mate I'm just building it back up in general '94 guise as it had been made to look like a '95 when I bought it.

Excuse my ignorance but I don't even know who Kurt Nichol is 🙈😂. I mentioned prior I'm really not an MX guy at all - just always wanted one and this was an impulse buy / project last year that has gotten way too serious! 

I did finally manage to get around to building up the reproduction airbox yesterday, when I say building it really is only gluing and pop riveting the two halves together.

However as to be expected from a non OEM / aftermarket replacement it wasn't a perfect fit together when I first looked.

So for those interested in buying one I will shed some light - firstly it is an excellent quality replacement and would of gone together pretty much as is but I wanted it to fit snug all the way around.

I had to use a modellers knife/scalp to cut a few little areas out where the two halves didn't quite come together perfectly snug.

The tabs for the rivets needed enlarging with a drill bit as they were smaller than the locating hole.

Other than that I just taped it all up as not to get glue everywhere. Used some plastic / silicone adhesive. Pop riveted together, G clamp at the bottom and left to dry for 24 hours. 

Very happy with the result.  

The finish is matt, I'm sure the oem finish is shiny? So when I go over the tank again I will buff this up to a shine👍.

As I mentioned previous , I wasn't going to touch the motor as the bike was sold to me under the pretense of having a 'fresh piston & 'good barrel'

Can't restore/rebuild a bike and not the engine?! Obviously not. So thankfully curiosity got the better of me and I stripped if down.

Piston did indeed look low hour, removed the cylinder however and ..🤦‍♂️

Found a lovely little crack on the head surface right on the water jacket, assuming it has been stood up through winter with no coolant mix and this is the damage result!

Damn, find someone to repair it? Beyond my capabilities for sure.

I found an absolute genius (do not use this word lightly) in Russell @ badfootcustoms

(Please check out his Facebook and if you are in the UK, very handy man to know!)

Here are the results,  cylinder repaired as good as new & off for re plate next week.

I ordered up a full rebuild kit for the engine but didn't spec a brand of piston, the chap who sorted me out has sent me a wossner forged item, I've read mix reviews about running these? Would I be better off just using a standard cast piston?

Anyway, pics ...

Cheers fella - I'll get on the YouTube and google and have a look!

Having never done any suspension work before I sent mine away to Ross @ Motopro for a full service.

• New seals 

• New bushes

• New bumpstops 

All genuine Honda parts.

I had already cleaned up the shock in the parts wash, chosen not to powder coat the spring, where do you put a stop to it🙈😂 I didn't intend on going this far but it's nice to keep some patina.

Still not got stuck into any meaty bits but did some little bits today.

• Replaced all wheel bearings & seals in both hubs

• New tubes in both wheels & rim lock on rear 

• New discs front & rear 

• Fitted new sprocket

• Test fit new airbox. 

Obviously had to have a quick mock up!

Think it's going to look real nice when it's done😎

After almost 4 years of owning this bike & it still not being finished, I'm back on it & hoping to have it built back up for Christmas !

One last little bit of repair work to do on the subframe and then the frame will be painted.

Carb needs rebuild when the kit arrives, bar that maybe a few little bolts to buy & I think that's the parts sorted.

I've just rebuilt the calipers, both master cylinders this last week. 

More pictures to follow once I start building it back up.

Finally finished the fab work on the frame.

New tank mounting brackets made where the old ones had been chopped off , the previous owner ran it with a bigger tank & for some reason had chopped the originals off and just drilled through the frame for a long bolt . All mocked up before to make sure the tank was in the correct place👍

The subframe strengthener / plate had also been ground off for some reason so made a new one ( I decided against drilling the holes like the OEM Honda bracket as it is just not needed and would require loads of work as they are oblong rather than round.

Ready for primer & paint !

@sandman768  Bike looks lovely👍 

And yes I am full tilt on it until it's finished now , I should of done it years ago but other bits and bobs got in the way !

I'm afraid to say once it's been shaken down & run in I will be selling it. 

I'm no Motocross rider in the slightest, although I love it! I just bought this as a 'quick' project when I first moved into my bungalow with garage , before I sorted my unit out , thinking It would take me a month or so !!

I've ended up going way too far with it really, spent way too much money but hey, someone's going to get an absolutely cracking 1994 Cr250 when it's done.

I will probably get a slightly newer 125 eventually once my son is a little older and he moves onto a 50! I don't need anything particularly quick to chase him about on his lt50 so I may end up with a little klx110 in the meantime .

And regards the welds, I did look at the factory honda welds and think.....👀 Really, lol. It's only in a slight dusting of primer at the moment so I could finish the welds off and do the bits you have mentioned , don't know if would affect re sale value, then again , it's not a genuine survivor, low hour bike so I guess it wouldn't matter !

Frame nearly painted.

The pro circuit pipe had been sat in my garage from new and had collected quite a lot of flash rust, so maybe sacrilidge but I cleaned it up and painted it black. The OEM expansion chamber is black so I thought give it a try !

Also looking to have a new end cap made up for the silencer, the chap who repaired the cylinder has the tooling to make one 

*Picture stolen from Google of the stinger tip

Engine ready to go in, just needs replacement kick start bolt as that was misplaced.

Gear lever straightened. Good to go 

Last few little bits on order, still the carb to rebuild .

Tidy and clip the hoses out of the way & it's nearly ready for the first kick.

Edging closer, one last cheeky mock up . 95% done.