2002 Honda CR250R Rebuild (finished)

JMX82
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11/19/2014 12:21pm Edited Date/Time 10/27/2016 2:56pm
Bike is my brothers ride and it's former Team CAS Honda GP bike ridden by a Finnish rider Jussi Vehviläinen in world championship series back in 2002. Sadly the most of the factory parts are gone, but the bike still has a really cool history. It has been my brothers ride for a ten years now and it has been ridden hard with very little maintenance over the years. The plan is to rebuild the engine and restore it to its former glory


This is what bike looked before rebuild started:




This is what the bike looked like back in 2004. The goal is to make the bike look same again





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JMX82
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11/19/2014 12:34pm
I was able to get the original Team Cas graphics re-produced by http://www.motosticker.eu/ in Latvia. The decals turned out pretty good and fairly close to original design.



We got new plastics kit for the bike and applied graphics on them. We where also able to find a used airbox in a good shape to replace the old broken one.







JMX82
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11/19/2014 9:16pm
HRC frame needs a bit cleaning










Engine waiting on the floor to get rebuilt and cleaned



CR250Rider
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Moses Lake, WA US
11/21/2014 1:01pm
Very cool. Request pic of the inside of the cylinder at the ports and such. Curious what work might have been done there.

The Shop

JMX82
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11/24/2014 9:57am
CR250Rider wrote:
Very cool. Request pic of the inside of the cylinder at the ports and such. Curious what work might have been done there.
Most of the special parts are unfortunately removed from the bike by the Cas Honda team or the previous owner and it has got stock cylinder with only casting flaws cleaned from the ports.
FGR01
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AZ US
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1334th
11/24/2014 10:57am
Wow, there must be some serious hours on that bike. Look at the amount of material removed from the clutch cover! The Honda text is almost totally worn off.

Is there anything special about the frame other than the skid plate mounts?



JMX82
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11/25/2014 11:41am
Only special thing besides the skid plate mounting in the frame I have noticed is the extra brace in the swing arm in front of the shock. Here's the picture of the brace. Sorry about the messy swing arm. I haven't had the time to get it cleaned yet



I started to dismantle the motor today. The clutch seemed to be in a good shape






The piston looked pretty toasted






The cylinder seemed to be fine



JMX82
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11/27/2014 10:14am
Got some parts soda blasted












mxBryan
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11/3/2013
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BE
11/28/2014 4:26am
FGR01 wrote:
Wow, there must be some serious hours on that bike. Look at the amount of material removed from the clutch cover! The Honda text is almost...
Wow, there must be some serious hours on that bike. Look at the amount of material removed from the clutch cover! The Honda text is almost totally worn off.

Is there anything special about the frame other than the skid plate mounts?



Yes, They also have a brake pedal guard mounted on the right side of the chassis (as seen in the picture).
The mountings were welded to the frame by the factory.
More knowledge about HRC frames i don't have.

I'm excited to see this project finished !



JMX82
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11/28/2014 11:13am
Made a tool for splitting the cases and got it done



















I used a fellow vitards system to store engine bolts



JMX82
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11/30/2014 7:47am
Got some parts for the bike yesterday




Carburetor soda blasted. I need to get new gaskets for it before I can put it back together




Frame washed with alloy wheel cleaner. It worked really good and the frame is now fairly clean







JMX82
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12/1/2014 12:43pm
Today I applied decals to new fork guards



Matt Fisher
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Visalia, CA US
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1084th
12/1/2014 10:16pm
That ignition looks strangely familiar... Tongue

Keep up the good work, it's coming along nicely.
JMX82
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12/9/2014 11:31am Edited Date/Time 12/9/2014 11:32am
That ignition looks strangely familiar... Tongue

Keep up the good work, it's coming along nicely.
Thanks to Matt's old CDI unit the bike has good spark =D

Got some more work done to the bike.

Removed bearings from the cases by using a electric stove plate. After 15 minutes on the stove the bearings just drops off from the cases almost without any assistance.



Connecting rod was replaced with new prox unit in a local machining shop



Soda blasted the engine cases with my Mcgyver style blasting cabinet made from cardboard box, duct tape and clear plastic bag.







JMX82
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12/12/2014 7:51am Edited Date/Time 12/12/2014 7:59am
I found a possible problem from the right side engine case. There is a small hairline crack in intake channel near where the reed valve is placed. What should I do? Use JB Weld to seal the crack or get it TIG welded or buy a new engine case or just let it be?





Got some parts for the build too. Used reed valve block from a friend with almost new reeds and red seat cover from ebay.







JMX82
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12/18/2014 9:27pm
I brought engine case to local welder. He tested the case with soap water and compressed air. He poured the sop water to one side of the case and blow compressed air to other side. There where bubbles coming out spot where the crack is, so it's definitely going to need some welding. I hope the welder is going to get it done today.
G Force
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Winnipeg CA
12/20/2014 9:44am
Great work! Cant wait to see the final product!
JMX82
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12/20/2014 1:51pm Edited Date/Time 12/20/2014 1:58pm
Got the engine case back from welder. It needs some grinding to clear the reed valve but otherwise it's looking good




Some more parts arrived too



Rebuilt carburetor with new gaskets and breather tubes



smoothies862
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745th
12/20/2014 3:30pm
can you slide that carb over a bit? i want to read that articleTongue
looking great so far. another welder to the rescue. the world needs more welders.
you know this bike needs a video when youre done,right? braaap
JMX82
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12/29/2014 11:49am
We made some progress on the build today. Engine bottom end is almost ready with new seals and bearings. Clutch plates where good so they didn't needed to be replaced.















JMX82
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1/11/2015 9:24pm
Finally got some time to continue rebuilding the engine.

Bored exhaust bridge lubrication holes to new prox piston



Soda blasted engine side cover



Continued assembling the engine















mxfiend
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Riverside, CA US
1/11/2015 10:20pm
i was under the impression that the pro x did not need to be drilled out vecause it is forged and not cast?! would really like to know as i am also replacing every bearing seal and moving part on my 03 as we speak. juat waiting on a full crank andd vforce then i will be assembling
mxfiend
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1/11/2015 10:23pm
oh and btw sweet build
JMX82
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1/11/2015 11:33pm
The holes are for exhaust bridge lubrication and cooling. It doesn't make any difference whether the piston is cast or forged. The Prox piston that I used is made by casting.
mxBryan
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BE
1/12/2015 12:51am
I also just bought a 2002 honda CR250, These are known for breaking exhaust ports correct ??
Does it help or stop the problem if drilling holes in the piston ?
JMX82
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1/12/2015 9:16pm
mxBryan wrote:
I also just bought a 2002 honda CR250, These are known for breaking exhaust ports correct ?? Does it help or stop the problem if drilling...
I also just bought a 2002 honda CR250, These are known for breaking exhaust ports correct ??
Does it help or stop the problem if drilling holes in the piston ?
Yes that is true. I hope the holes in the piston will make the cylinder last longer.


The exhaust pipe on the bike is made by Doma Racing

1/12/2015 10:03pm
mxBryan wrote:
I also just bought a 2002 honda CR250, These are known for breaking exhaust ports correct ?? Does it help or stop the problem if drilling...
I also just bought a 2002 honda CR250, These are known for breaking exhaust ports correct ??
Does it help or stop the problem if drilling holes in the piston ?
JMX82 wrote:
Yes that is true. I hope the holes in the piston will make the cylinder last longer. The exhaust pipe on the bike is made by...
Yes that is true. I hope the holes in the piston will make the cylinder last longer.


The exhaust pipe on the bike is made by Doma Racing

JMX82- the Doma is suppose to be the best pipe for the CR 250. Dirt Rider did a test in 03 and were blown away by the performance of the Doma.
JMX82 do you know where I could get a Doma and have it shipped to the USA?
Nobody over here carries them and I've tried contacting the company with no response. I'm not really happy with any of the American pipe makers for my 02 CR 250 and I tried the DEP pipe and it made a lot of power, but was pipey and not a lap time powerband if you know what I mean. Who do you buy your stuff off of? Do they speak English? Any help would be much appreciated !
JMX82
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1/12/2015 10:54pm
The Doma pipe came with the bike we bought it. It has smooth and strong power delivery starting from very low rpm's. It makes finding traction really easy and riding the less tiring

I'm sure someone will ship the pipe for you in the US. Here's some web shops who are selling Doma pipes:

http://www.knobby.eu/en/art/exhaust-pipe-silencer-doma/doma/doma-2-stro…

http://www.24mx.co.uk/doma-two-stroke-exhaust-pipe

http://www.doma-auspuff.de/component/page,shop.browse/root,33/category_…

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