1996 cr250 build ...refresh

If the frame tube is not too bad you can weld tabs in the dent & heat up the area then use a dent puller to pullout, if the tube us flattened , they are easily replaced by a competent weld/fab shop. Mine was not too bad so I did it myself. My brother and I have a welder & body shop experience. You wan to make sure the frame rails are not pushed up too bad, an easy way to check this is to use your lower engine mount bolt as a test, with engine out, see if the lower bolt slides through both frame rails easily, if it does the rails are still aligned good, if the bolt does not slide through the rails easily, one of the rails is pushed up from impacts, if that is the case, I would have the tail replaced, make sure you bolt in both engine mount bolts & swingarm bolt prior to cutting & welding, as they will provide alignment for the rail replacement. I use a fab shop that builds/repairs dirt track car frames & crash rails, they bend, form & weld this type of tubing all the time... I have no idea why one of the gears broke a tooth off... The first lower end rebuild was done by one of the best Honda techs in my area, so nothing was done incorrectly. I had around 11-12 hrs on the bike before the gear broke, very clean break, a tooth broke & jammed another gear causing the shafts to lock & put pressure on the case where the clutch actuation arm area is...Luckily I was in a low speed tight turn & just pulled the clutch in & pushed it back to the pits... If it had let go in a high speed section, it would have destroyed a lot more...we did replace a couple gears during the first rebuild, but overall my tech said the tranny look pretty good. The bike had some good time on it before I bought it, so who knows how many hrs were actually on the gears. The next time I go into my shop I will check to see what gears we replaced back when we first rebuilt it, curious to see if one of the gears I replaced broke...I should be firing this thing up sometime this week...I"m pretty confident I did everything correctly, I"m still learning, but the last few bottom ends I have done have worked good. Post up your build!

My cr did not start out as a very clean low hr bike...I had been looking for over a year and it came up for sale, it had a lot of Pro Circuit parts on it, turns out I knew the original owner, as the title still had his name on it...so I talked to him & he told me he had pro circuit do just about everything they offered in 96. Unfortunetly after he sold it, the next few owners were not so kind to it.....It came with a bunch of spares and really good period correct aftermarket parts...so I bought it knowing it was a full rebuild of everything.....

Should have it finished up later today .....thought I would do a quick cleanup in the pipe ...2 hrs later it's good enough..

Just have to add coolant & fire it up...for the guys that have these bikes, if you find the frame holes by the steer stem an eye sore, I have a simple solution....Ktm makes a push in plastic cable/wire guide works good, cost under 5.00$

I'm looking forward to testing out my work....have about 3 months to go before the ground thaws out!