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Nice notches!
You may find it difficult to find a good used one, you may be better replacing with new.
But since I’m in it this deep I might as well take it a bit further and do more work where I can. Tedious but it’s a game of small improvement at this point that will add up to a better engine.
I started on the left side case today and ended at Match City! The case was ported to match the cylinder texture and I’ll continue to work it into the crank housing. It will take me a few hours to finish it up.
Yet it still works better than a stock Suzuki clutch🤦
I just put hinson plates in my cr last night. I only used half of the springs and it’s an extremely stiff pull. The other half are Barnett, I may just run all Barnett eventually. It grabs great though
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Drill a new hole in your clutch lever, and change the leverage ratio...
Why do that on a Honda? Don’t they pretty much have the best leverage ratio? Even Works Connection copied it for their perch/lever sets.
To make it even lighter!
When guys proudly show off their hydraulic clutches, I like to see the WTF moment when they use my clutch lever!
The crank housing is part of the intake so I textured it to go against the flow of air/fuel to help create tumble for better mix. Every engine I’ve done this too I can feel a major difference in how it runs way down low.
Just need to finish cleaning mating surfaces and also clean water jackets.. Time for the other case.
I have a Boyesen Rad Valve for the '01 engine, and possibly a screw top Keihin PWK, if you're interested in them. Sitting on a shelf for years now.
I had an '01/'03 Hybrid for quite awhile (cratered the engine on the '03, had an '01 I wasn't riding). Great bike: 3rd gen handling along with the broad HPP engine.
Also to note, I have PDF versions of the '00-'01 CR250 and '02-'03 CR250 Service Manuals somewhere on my PC. These things are super durable and easy to work on though.
Edit: Another thing I just remembered, depending on the year of the forks you're using, the front brake caliper hanger has a different spacing from '04 and up (smaller) compared with '03 and earlier (larger). Most oversized brake rotor kits will fit the '04 and up, but not the smaller. I'd check your setup to see if you need to do something now before waiting until putting the wheel on.
How do you get that texture? Is it some kind of porting flap tool?
Nice bike! From experience you know exactly why I’m building another one of these!
I would be interested in the rad valve and the carb. What are you thinking you want for them
I use a variety of different bits for my dremmel along with fine hand files. I only use the flap wheels for polishing the exhaust port and other bits mainly.
Yeah right on. I hv the same lever I bought it back in the 90 ,s . They called it ez pull lever. I should make a spare lever . I don’t want to ruin a lever . I think it would be easy . Is it easy to drill ? I tape the throttle wo over night . That lightens the spring a little, easier throttle pull.
Yes, it's easy to drill.
If you don't have a drill press, you can use a battery drill, but put a collar/sleeve/tube over the drill bit to control hole depth.
The new way pictures upload on this site is different and way more difficult! I’ve been on another mission and haven’t made as much progress as I would like. But we are moving forward!
Top end was massaged just a bit and bottom end was perfectly matched to the cylinder. All new OEM bearings, shift forks, crankshaft were installed. I also hand polished all the shafts inside the engine for smoother operation.
I also trimmed all the excess gasket material from the center case after it was assembled. It really cleans up the look of a rebuild when it looks factory fresh. Time to get the bottom end in the frame!
Pit Row
Major stokeage!
Modified the frame and got the bottom end mounted. Made a little u-turn scribe to make sure I got the bore right on both sides.
I’m starting to get excited!
great work
I hope to make the those Honda technicians proud with my build!
It’s not on Tokyos level though! Yours is outstanding.
I would love to find one of the works ignitions with the gear position sensors. That would be icing on the cake.
On a side note I’m not sure who the rider of that number 6 honda was but their lever positions are/were ridiculous.
I’ll be posting an update on my build tonight or tomorrow.
#6 was Ryuichiro Takahama.. yes, he had the levers angled up at the sky.
To fit the gear position senor and make it work, you would need the HRC cases, the sensor itself, the full HRC ignition that it plugs into, and the ignition advance button that mounts on the handlebars.
You don't like keeping your elbows down like Ryuichiro Tamahama?
I would be ok with all that! This is a bike I don’t plan on selling
I’ve been keeping my eye out for a genuine works crank for a while now too.
Ha!
I need all the help I can get to keep my arms off my sides. 😂
Hinson clutch!
New actuator rod bearing.
Plus a works magnesium inner cover that I picked up from a fellow vital member here when I raced the Glen Helen 2stroke nationals in 2020. This thing is light! Plus an old school works replica clutch cover that I need to work on a bit still.
Wossner piston, polished exhaust valve and gates, matched gaskets, polished head, along with cleaning up the ports a bit more. Doug from Forged in Fire would say “It will kill”
I even assembled it with a little trick I picked up along the way to reduce tool marks
You’ve had that cover laying around for 3 years? Geeze man! That was a fun race though and was good meeting you there. Planning to race it again on this Honda?
Post a reply to: The best CR250R that Honda never built.