1994 honda cr 250 roach to racer, almost completed. Build recap video link

mitchlovin
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mitchlovin
Edited Date/Time 4/30/2022 6:49am
Well i did it again, bought this bike as a parts bike for my 96 mcgrath tribute bike. It ran, but i couldnt stand to part it out, so here i am trying to make 90s moto great again! The bike sat in an enclosed trailer for 7years never started, washed or seen the light of day in that time. I was actually working at the house next door and saw the rear fender inside the trailer. I started talking to the owner, he said he would never sell it, it meant to much to him. I took his phone number anyways and carried on. I called him 2-3 times a year for a couple years and he finally decided to sell it. $400 bucks later and a hellava struggle to load it due to the flat, dry rotted tires and frozen front brake caliper, it was mine


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mitchlovin
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mitchlovin 9/27/2021 7:24pm
9/27/2021 7:24pm
Tear down began And i found some not so pleasant surprises


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FarleyMX25
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FarleyMX25 9/28/2021 4:27am
9/28/2021 4:27am
I’ll keep an eye on this post I also have a 94 250.
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mitchlovin
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mitchlovin 9/28/2021 5:17am
9/28/2021 5:17am
Power washed ,scrubbed, broken down into smaller “subsections”.


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bh
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bh 9/28/2021 6:01am
9/28/2021 6:01am
What’s the plan for the left case? I would imagine they are getting pretty hard to find used in decent shape.
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The Shop

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TooOld4WFO
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TooOld4WFO 9/28/2021 8:18am
9/28/2021 8:18am Edited Date/Time 9/28/2021 8:20am
That may not even be an issue requiring replacement. That is a steel insert next to the swingarm. It’s a sealed area separate from the crankcase.
I would use Devcon or your favorite epoxy. Once you get cases split that’s an easy fix.

Plus that looks cut to me. Must have had a seized in swingarm bolt.
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FarleyMX25
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FarleyMX25 9/28/2021 8:30am
9/28/2021 8:30am
If by chance you have the broken off piece you can send it to trick engineering and he can fix it back like it never happened. He may be able to fix it without the broken piece He does amazing fab work.
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mitchlovin
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mitchlovin 9/28/2021 8:41am
9/28/2021 8:41am
Mocking up the 04 crf front fork . I decided to do the all ballz bearing kit as i want to keep the 94 front end complete and usuable

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FarleyMX25
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FarleyMX25 9/28/2021 11:37am
9/28/2021 11:37am
mitchlovin wrote:
Mocking up the 04 crf front fork . I decided to do the all ballz bearing kit as i want to keep the 94 front end...
Mocking up the 04 crf front fork . I decided to do the all ballz bearing kit as i want to keep the 94 front end complete and usuable

How exactly does this work? You get a complete front end from the donor bike and then the bearings adapt it to fit?
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mitchlovin
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mitchlovin 9/28/2021 5:46pm
9/28/2021 5:46pm Edited Date/Time 9/28/2021 5:50pm
Stripped the engine down, split the cases and found the original piston and crank in it. I sent the cylinder and crank off to ken oconnor racing to be rebuilt and replated as it was slightly worn. In the meantime i turned my attention to the frame and subframe

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mitchlovin
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mitchlovin 9/28/2021 5:55pm
9/28/2021 5:55pm
Ive meet alot of cool people with some serious talents but aaron seymour is a top notch fabricator. I spent alot of time
Researching case repair. I stumbled upon his instagram page and saw he was in the middle of his doug henry build. I sent him a message and he offered to see what he can do. The pics speak for themselves , along with being a super down to earth guy. The man is a wizard with a tig welder !!!
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mitchlovin
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mitchlovin 9/28/2021 5:58pm
9/28/2021 5:58pm
mitchlovin wrote:
Mocking up the 04 crf front fork . I decided to do the all ballz bearing kit as i want to keep the 94 front end...
Mocking up the 04 crf front fork . I decided to do the all ballz bearing kit as i want to keep the 94 front end complete and usuable

FarleyMX25 wrote:
How exactly does this work? You get a complete front end from the donor bike and then the bearings adapt it to fit?
Yes its a conversion bearing. Most of the honda bearings are the same if i remember correctly? This kit comes with the necessary spacer to install the aluminum frame triple clamps on the steel frame, as the steering stem is longer on the aluminum framed bikes
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TooOld4WFO
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TooOld4WFO 9/28/2021 10:32pm
9/28/2021 10:32pm
Yes Aaron is a very good man. He has amazing skills with design/fabrication/welding. He is a credit to the moto community for sure. Loads of humility too.
What’s not to like about him.
Glad he took on your repair.

Bike is going to be so stinking sweet. Keep the pics and info coming.
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mitchlovin
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mitchlovin 9/30/2021 6:21am
9/30/2021 6:21am
Sent the cases out for vapor blasting along with some other small parts for the linkage etc. I ordered all oem engine bearings, seals and transmission bearings also
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mitchlovin
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mitchlovin 10/2/2021 7:24pm
10/2/2021 7:24pm
Crank back from rebuild and all new oem bearings and seals. Crank was rebuilt using a prox rod kit.






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mitchlovin
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mitchlovin 10/5/2021 6:12am
10/5/2021 6:12am
New pro x piston, cylinder back and installed. Used the spec bolt nickel works kit. Looks pretty trick




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mitchlovin
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mitchlovin 10/12/2021 5:59am
10/12/2021 5:59am
New clutch basket install. The wife wasnt exactly thrilled i used the new stove to heat the basket to install the drive ring !!


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mitchlovin
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mitchlovin 10/14/2021 9:17pm
10/14/2021 9:17pm
Halted work on the engine to swing down to the powder coaters and pick up some goodies. Heres a sneak peak

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sandman768
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sandman768 10/15/2021 11:42am
10/15/2021 11:42am
The 97-2001 water pump shaft drive gear is aluminum not plastic if you want upgrade the pump drive gear👍
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mitchlovin
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mitchlovin 10/20/2021 4:56pm
10/20/2021 4:56pm
Ran into a hiccup when installing the inner clutch cover. On tear down i noticed the water pump cover was siliconed
On and missing a bolt, i just figured it was a cheap fix by the previous owner. Boy was i wrong

JMX82
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JMX82 10/20/2021 11:59pm
10/20/2021 11:59pm
I had similar situation with my -84 CR125. The broken bolt came out easily with reverse thread bolt extractor
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mitchlovin
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mitchlovin 10/22/2021 7:40am
10/22/2021 7:40am
JMX82 wrote:
I had similar situation with my -84 CR125. The broken bolt came out easily with reverse thread bolt extractor
Had a good buddy use an end mill bit on his bridgeport!
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mitchlovin
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mitchlovin 10/25/2021 12:17pm
10/25/2021 12:17pm
Slid the engine into the freshly powdercoated frame, sprinkled in a bit of titanium too



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mitchlovin
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mitchlovin 10/27/2021 6:41pm
10/27/2021 6:41pm
Sent the extremely hard to find stock radiators out to icw for repair and cage bracing



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mitchlovin
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mitchlovin 11/1/2021 2:08pm
11/1/2021 2:08pm
Mounted them to the frame using some trick drilled aluminum washers, new oem rubbers, the bolt hardware kit for the steel framed cr has been a live saver




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mitchlovin
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mitchlovin 11/6/2021 11:14pm
11/6/2021 11:14pm
Had the swingarm filled and blended. Vapor blasted linkage components , fresh bearings





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mitchlovin
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mitchlovin 11/13/2021 4:16pm
11/13/2021 4:16pm



Faster usa for the rims/ spokes, cerakoted the stock hubs , new bearings and an oversized hrc replica rotor for the front
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mitchlovin
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mitchlovin 11/17/2021 8:13pm
11/17/2021 8:13pm
Tried out the pryme mx cleaning wheels on a caliper. Pretty impressed with results






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mitchlovin
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mitchlovin 11/26/2021 8:04pm
11/26/2021 8:04pm
Cleaned up and rebuilt an 05 crf front brake assembly i bought off ebay to work with the tc 47mm showas. Also sent the rear brake pedals up
To aaron for some massaging

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