02 CR 250 compete rebuild

[B_Rad]

So a while ago now I completely stripped and rebuilt my bike, and along the way I had alot of help from this very forum. I said I would post a progress report on the build but with time limitations and being a slave to the shed, I never did.
Well these type of threads are my favs, so I figured I would go back in time a little and make the posts as promised.
There is a little break in the time line though. 3/4 into the build and my main digi body shutter decided to cark it and it took a few weeks (not to mention the $886) to get it repaired so I missed some shots.

So to start off this is how the bike looked when I got it.




You may notice that the rear mudguard has a little bit of frankenstein syndrome going on to keep it together



Seemed to be in fair order but had a top end knock. Turned out to be long over due for a top end rebuild and the exhaust bridge was cracked so bad that the cylinder needed replacing.
So the strip down began







Both radiators had sever shape distortion from several drops so they needed a bit of encouragement to come square again.
Then I took to the frame. 5" grinder with a buffer pad and "purple" chrome polish. Inside the frame was nothing more that a rag, a finger and alot of time

[B_Rad]

When cleaning up the swing arm I came across this. The chain guard was on it, but underneath it had worn through. Oh dear





So I chucked a blob of weld on it. Had to be a significant amount to make up for the chain guard locater tab







Then I shaped the inner side with a air die grinder till it matched the bearing outer.
Then I found a cap in the shed that was the same size as the outer on the opposite side



Put it on the side that needed re shaping and traced around it





Then took to it till I had it how it should be with a 4 inch flap disc

[B_Rad]

Then my stuff turned up. I can't tell you how excited I was when this package arrived.



Included was a set of plastics, new cylinder, FMF SST, FMF titanium shorty, Weisco flat top kit,Weisco crank, A complete set of bearings for everything on the bike, a Keihin PWK 39, (wanted the 38 but couldn't find one for the right price) V Force3 reeds, Gripper seat cover, Twin air filter, Wave rotor discs, New kill switch. Also Bars, clamps grips etc as my very last ride ended in an endo that klled them all in one.
There is also a new rear brake cylinder in there thanks to eBay as mine was toast. Also came with a rebuild kit that came in handy later on in the story.

[B_Rad]

So bearings fitted every where next. That lead to this thread over HERE

Then came building the donk. Now I kinda wussed out a bit here and got a mates neighbor that works in bike shop to install the crank mains and crank.
I actually did the same thing when I built my 350 Chev. I had a mid journal crank milled down to fit in a small journal block, and had the bottom end installed by someone more in the know. I'm sure I can do it, but when it comes to the bottom end ,I just need the assurance it's done right. And until the day i can do it alongside someone that knows what they are doing, I'll leave it to those with the experience. I also had my suspension renewed by a suspension guru.



The new carb and reed cage. I put some gasket goo around the cage to ensure a proper seal.

[B_Rad]

This is where my camera died. I did manage to find two I took on my phone though.





And with the tank and seat sitting on to see how it was going to look. Yes I was keen.

[B_Rad]

Then were straight to the almost complete. All I was waiting on here was the chain and sprocket kit.

[B_Rad]

Couldn't wait for my sprockets to turn up so stuck on my old front and rear sprockets plus a mates old chain and took it for it's first run in ride.











Unfortunately using an old chain in a combo with an alloy rear sprocket wasn't the best idea and I was home in under an hour with no rear teeth. but boy was it making some power.

[B_Rad]

After its first ride when I got my new chain and sprocket kit







Took me a little while getting used to hitting the ramps with the new found power, but once used to it, it made life alot easier.

[B_Rad]

And then once finally confident in ramping again, I took to the rear guard (makes nac's alot easier) and cut in my grab holes. And also added the pretty sticker kit too.





More has gone on since this, but thats where I'm up too with pics. I'll shoot some updated ones in the near future and add them to this thread.

Cheers......Brad

[Orido]

wow this is one very nice bike.
What camera are you using, I can sense a DSLR

[rossim22]

That's an awesome cr250. i was thinking about taking the stock graphics off of mine too, but i wasnt sure what it'd look like.

[pragmatic393]

Awesome restore!!! You have serious skills, Bro

[kjjz28]

Awesome bike and good pics/description. Might be PM'ing you when time for work on my '03!

[B_Rad]

Cheers everyone. As soon as it stops raining I'll go outside and shoot some updated pics with the info.

Originally Posted by Orido

wow this is one very nice bike.
What camera are you using, I can sense a DSLR

Most pics of my bike outside would be with my Canon 1DMKIIN and a 70-200 2.8 IS L. Inside would be same body but a 17-40 F4 L

[2strokesurvivor]

Nice ride B_Rad! If I got my '03 looking that nice, I don't know if I would ride it. Very nice work.