1991 CR250R Project Bike Build

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10/17/2019 11:42 AM

Master cylinder + rear brake caliper reassembled.
Everything is new inside.

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Motocross Suspension Revalve

10/17/2019 12:57 PM

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10/20/2019 9:20 AM

Pending the arrival of other parts to continue to advance on the restoration of the bike, I looked at the damper and after taking the measures, it turns out that the damper of 250 CRF 2008 and longer 30 mm that the original CR, so it will be necessary to make a wedge to shorten it to be able to mount it on the bike, the original being largely outdated in technology and especially rod diameter.
I planned to leave it at its original length because it seemed to me that the fork KYB PSF of my 450 CRF 2013 was longer, but after the assets put side by side, they are the same length, so if I leave the 'shock absorber dive, the bike will poke nose (ok it will be super handy like that, but I lose stability in a straight line with the risk of guiding, so not to lose too much race of the rod of the damper, I'm going to climb a wedge (I have it but it's steel, I'm afraid it's gnawing the rod, it's this piece that helped me to make the plan with the odds) and I would then modify the value Race Sag and Free Sag, to balance the bike.

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Motocross Suspension Revalve

10/20/2019 9:23 AM

High engine returned home, almost better than new.
L.A Sleeve - Wiseco Piston and all in original dimension.

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Motocross Suspension Revalve

10/20/2019 10:26 PM

loving this build, i want a 95-96 cr250 build someday.

just a heads up, dont use normal or petroleum based grease in the brake pins, it will swell and ruin the seals/boots very quickly, the proper gease for those is this silcone based stuff made for brake pins/sliders. can get it at any auto parts store

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10/21/2019 11:15 AM

Just went through all the pages. Impressive effort. Realize that many many members look at these builds for inspiration.

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10/21/2019 2:44 PM

adam8781 wrote:

loving this build, i want a 95-96 cr250 build someday.

just a heads up, dont use normal or petroleum based grease in the ...more

ok the Maxima is not suitable then?

I put this one there because it is waterproof

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Motocross Suspension Revalve

10/21/2019 2:48 PM

RCMXracing wrote:

Just went through all the pages. Impressive effort. Realize that many many members look at these builds for inspiration.

Thanks wink

I almost had the same in 1988, same engine and frame, happy to have found the 1991 model that I wanted before stopping the MX a few years.

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Motocross Suspension Revalve

10/21/2019 2:50 PM

To make the 2008 Showa look like a Showa or KYB 30 years ago, I did a little fading, because it was worn on the nitrogen tank at the boot, it was not very classy on a bike that will be almost like new when it is finished (ie next year), there it adds a certain charm I think, it is a little more Vintage smile

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Motocross Suspension Revalve

10/21/2019 3:30 PM

Maxx MRP wrote:

ok the Maxima is not suitable then?

I put this one there because it is waterproof

correct any normal grease meant for bearing will swell and ruin the rubbers.

get the silcone brake grease in there
https://images-na.ssl-images-amazon.com/images/I/41DwwjgRZLL._SX466_.jpg

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10/21/2019 3:41 PM

adam8781 wrote:

loving this build, i want a 95-96 cr250 build someday.

just a heads up, dont use normal or petroleum based grease in the ...more

Maxx MRP wrote:

ok the Maxima is not suitable then?

I put this one there because it is waterproof

adam8781 wrote:

correct any normal grease meant for bearing will swell and ruin the rubbers.

get the silcone brake grease in there
...more

Ok, nothing is going up again, so I will quickly remove the maximum grease and go up with silicone grease.
thank you for the info

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10/22/2019 11:40 AM

Well ... after finishing the suspensions in progress (and therefore a preparation of 125 KX of 2004, that's why I compare the 2 shocks) I looked at the problem and so I can keep as I had seen, the shock of the CRF, positioning the old bearing that I had extracted and put in the frame, it passes and does not touch as I said before, I need in this case now just the lower shock mounting part of KX 125 2004/2008 or RMZ and KXF 250 from 2004/2005.
Or find a person well equipped and able to make me this part to measure, because I do not believe that it exists, at least more in the KYB catalog, the complete rods are out of stock and more apparently manufactured, but an email to my friends from KYB Europe will confirm to me if it is still possible to have these complete rods or just the rear shock foot.
In short, in the meantime, I need to find the emergency solution

and I can not anymore see the frame in this state, vividly repainted.

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Motocross Suspension Revalve

10/23/2019 12:05 PM

So I solved the problem, I'm given another rear shock, it comes from a 250 RMZ 2005 and it turns out that the lower attachment is the same dimensions as that of the CR, but with a rod of 16 .
So I'll see if it is complete, otherwise I would mix between KYB and Showa, so it will be either a Shoyaba or Kayasho laughing grin

and here are the holds that I was made, one plastic and one aluminum

but in the end I think I would not use it on this project, maybe on a next

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10/24/2019 10:53 AM

Not much done tonight, reassembling the cylinder studs and starting cleaning the valve.

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Motocross Suspension Revalve

10/25/2019 12:54 PM

Building or rebuilding a bike is enjoyable but it also takes time, a lot of time.
It is sometimes necessary to make concessions, sometimes to find the rare parts, sometimes to choose and to adapt solutions ....
In short it is not a sport of any rest, but when we like that, we enjoy.
So as you know from the beginning, I adapt suspensions of last generation and today I continue to think about the side of the fork and more particularly the triple clamps and the abutment of the frame.
So I blew the stop "original" which was not really like the origin, wear or modification to have a greater radius of action? I do not know, but the two sides already were not aligned.
So considering that anyway in its current state it could not fulfill its action, it jumped and I'm going to make a new one, once that is the part part in painting, or I find the plan for the attachment of the aluminum clutch cover protector.

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Motocross Suspension Revalve

10/25/2019 4:28 PM

You are killing it! So much work, respect!

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10/26/2019 1:37 PM

New shock received for the 250 CR, thanks to Steven for the donation of his old cushion of 250 RMZ, it is exactly the same spacing and identical fixations so it can be mounted directly on the bike, but of course a rod of 16 (which is more serious than 91) and I will review and prepare it, unless I make a mix with the Showa (to see after dismantling)

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Motocross Suspension Revalve

10/26/2019 1:40 PM

I continued a little on the abutment frame, assemble the two pieces of iron to the arc welding, then adjustment to the file tool.
more than refining the adjustment and then well it will weld properly on the frame.


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Motocross Suspension Revalve

10/27/2019 7:35 AM

Wow well made hand part!

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10/27/2019 1:55 PM

As promised, blank tests for the rear shock modification planned for the 250 CR, after studying several possibilities, I chose the starting one, namely a mix between a Showa and a KYB.
I will see later in use, if there will be need to return to some settings, but thanks to my experience since my start at 16, I very rarely had to return to my work, whether for me or for my customers (except evolution of those if they have to keep their bike) without wanting to appear pretentious, far from me this idea I leave it to others.
I do not say more about the changes that will be made, we will see later wink

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10/30/2019 2:47 PM

Arrival of the day smile
HINSON Hi-Performance Clutch Basket (no laughs anymore) and small washers alu for "Facory..ing" the CR laughing

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Motocross Suspension Revalve

10/30/2019 3:09 PM

since a few nights, I work a little bit on the transformation of triple clamps fork (it is not finished yet so we do not judge for now) in order to adapt not only to the frame (with its new stop that will be welded shortly) but go from a 450 CRF 2013 to 250 CR plastics of 91, so it was necessary to blow bindings and I should then drill and tapped for the front fasteners of the guard and the high fixation of the frontplate .
I also take the opportunity to transfer the traces of molding, to make the tees more "factory"
In short, you see, I'm very shit on this bike, but I want the final result is at the top and it makes some drivers want to live in the south-east of France, give me their motorcycles in restoration as soon as I have my new local soon (logically at the beginning of the year if all is well)

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Motocross Suspension Revalve

10/31/2019 5:04 PM

Work on the clutch basket
The Hinson basket like many others, are delivered without the gear which are therefore to be recovered on the old ones.
As you can see, the original one was + that fucked and impossible to rectify again since it had already been done many times, we can see very well the gap between each edge and the deformation + of the impacts of the discs, I had hope of the preserved to limit the costs but impossible, then with the luck that I had on the Hinson, as much to pass on the top.
Here are a lot of photos with each step done for the reassembly of the new bell.
"Maxx has no time to spare with twisted clutch basket and rusty bikes, there's bending sheet metal and welding in the air! MRP Garage's next challenge is already on track » laughing laughing

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laughing

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Motocross Suspension Revalve

11/3/2019 11:28 AM

HPP Valve Reassembly
For adjustment we will see once in place on the engine, so it's not for tomorrow again wink

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Motocross Suspension Revalve

11/4/2019 7:35 AM



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Motocross Suspension Revalve

11/12/2019 1:24 PM

Being momentarily up to date on the suspensions of my clients, I gave myself a few minutes to work on the new feet of the CR, I could do only one but tomorrow I do the second if I have time .
Being curious to know how it was under this ugly gray paint, since on the description they are noted to be made of stainless steel, so I stripped the paint then go to the brush and here I am with a very nice Factory, personally 'really like.

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Motocross Suspension Revalve

11/13/2019 11:40 AM

both are made

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Motocross Suspension Revalve

11/16/2019 12:46 PM

It's not going much forward right now on the 250 CR
I got 2 small scratches on the range of the gearbox outlet seal, a small shot of epoxy metal to be certain that there will be no micro oil leakage.

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Motocross Suspension Revalve

11/19/2019 1:06 PM

Hello everyone

Today some news

Thanks to the company JIVC ACCESS specialist sale accessories, equipment and parts for the bike, for its involvement in my personal project of restoration of my 250 CR of 1991, with the gift of this plastic kit.
JIVC ACCESS se situe 6 rue DE LA SABLIERE, 25600 VIEUX CHARMONT - France
https://www.facebook.com/jivcaccess

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Water pump and valve bearings received.

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More a few small parts that will also have their importance on the final result, even if it does not show ..
Handlebar mounting cones, coolant hose clamps, gearbox output, steering bearing set.

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Motocross Suspension Revalve

11/21/2019 12:35 PM

Maxx MRP wrote: Photo
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damn I've been watching this build and the only thing I've been saying to myself is man get rid of that damn pipe. But you pulled it off brother....Amazing work.

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