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  #31  
Old 08-05-2016, 06:14 AM
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Location: Norway
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Here are some updates on this build.

I got lucky!! A friend of mine called me and said he knew a guy that had a 2001 CR250 in pieces that he was going to sell. He had bought it with a stuck gearbox, and took it apart but couldn't put it together. So I bought it for almost nothing! The bike was a mess, but I got all the parts I needed. He also had a spare cylinder and much more.


I finished the Y piece. I grinded down the CRF engine mounts and welded in two pieces of aluminium in the two holes. Then I grinded down the welds.





Engine overhaul. New oem crank and bearings


Frame welded




CDI location





The airbox mod was the hardest thing. The new 1998 airboot I got did not fit at all!


The airboot from the 2001 bike was a better fit but was missing about 2cm


I ended up fabing up a adapter plate out of a 2cm thick aluminium block that fit the gap. Then glued/bolted it to the CRF450 airbox and the airboot from the 2001 donor CR250. I don't have a pic of the adaptorplate.


I made a coil mount that fit on the right CRF engine head mount on the frame.



2006 CR250 brakepedal with pivotbolt that clears the clutch cover on the CR250 engine. BIG thanks to FADED for this tip. I love when I can find bolt on parts!!



FINISHED!!










It lacks some power at the bottom, so I think I need to check the ignition timing and adjust the carb a little, but this thing is a blast to ride!!



It was a little muddy at the track when I did my first testing
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  #32  
Old 08-08-2016, 08:26 AM
cowboyona426's Avatar
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The bike came out nice, great job!
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  #33  
Old 08-08-2016, 03:00 PM
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Sweet!

Way to work through all the obstacles. Your bike turned out great!
Now it's time to sort out all the details of getting it set up and tuned,
that's the fun part.

Good luck with the rest and thanks for sharing a very cool project.
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  #34  
Old 08-09-2016, 04:25 AM
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Thanks for all the help and inspiration dogger!
The plan is to finetune the engine and check that everything works. Then over the winther I will do the suspension and a graphics make over. I can't ride with the CRF450 logo forever.
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  #35  
Old 09-20-2017, 01:20 PM
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Long time since my last update!

I haven't been able to ride in about a year due to a small crash a at race, but I injured my right wrist realy badly. A year later and I still can't use my hand like I want.

But now to the bike.
The only damage the bike got in the crash was a bent handlebar mount, a crack in the right radiator and a bent clutch lever.
I tried to fix the radiator but I gave up. I then came across this chinese dude that custom make radiators. I found a drawing online of the radiators for the Gen5 frame and the 92-01 CR250 engine, and sent a mail to china. 2 weeks later I got my radiators and it fit perfectly!! It even came with silicone hoses. The cost of the radiators where 200 dollars inc hoses. The quality seem realy good too.





Another thing I wasn't happy with was my airbox/boot setup. The 2001 airboot and 2cm tick alu adapter plate was to heavy and I think it restricted air flow too. So I bought a airboot from conversionparts500. This is designed to be used with the Gen5 frame and the CR500 engine, but I was willing to give it a try. And it fit! I had to strech it a bit on the lower part but that was easy compared the the old system I got. I wish I tried this the first time, would have saved my alot of work!



I also got a Magura hydralic clutch kit on it and a ěhlins steering damper 2.1 is being mounted soon.

Now winter is coming here in Norway, but in the spring I can finaly ride again hopefuly. So I will go over the whole bike in the winter, so I will post some updates along the way.

Last edited by Trusa; 09-20-2017 at 01:39 PM. Reason: Adding photo
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