2003 cr250 needs new life

[2strokesurvivor]

I am recently a new father, and I have not rode my bike on a track for over 1-1/2 years. My bike still starts/runs fine, but I would like to breathe some new life (and power) into the old beast. I am planning on a complete overhaul, and would like advice on the best parts for this project. I do not race, and therefore would like to do a big bore kit...as well as the basics of new exhaust, suspension work, vforce reeds etc. Any help would be great. Thanks. btw..here is the beast at day 0

[KKXR400R]

Originally Posted by 2strokesurvivor

I am planning on a complete overhaul, and would like advice on the best parts for this project. I do not race, and therefore would like to do a big bore kit...as well as the basics of new exhaust, suspension work, vforce reeds etc. Any help would be great. Thanks.

Lots of options here. It really is about personal experience and knowing what you want. It's taken me 3 years to finally get my CR the way I like it, only to have the wife buy me a new KTM so she could steal my baby away from me. Honestly, I think she was tired of me spending money on the bike.

If it power your looking for or just looking to move the power delivery around, you may want to give Eric Gorr a call/email. Just got some feedback from a friend of mine. He had his 01 ported for more low end (does not need race gas) and he absolutely loves it. I have the V3 reeds in my bike but without ever riding the stock reeds I couldn't tell you what the difference was. I can tell you the V3's had a little more Umph the the V2's. As far as exhaust goes, I like FMF just cause I thats all I have ever used. Heard some problems with the seams bursting out but I have never experienced this. I own the SST, Fatty and the Gnarly (current setup W/the "Q") and also have the Shorty and the "Q". I like the Gnarly and "Q" setup. Plenty of low end and I compensated with gearing to get over the 75 MPH mark. I want to pace it with the new bike (has a speedo) to get actual numbers though. Now the suspension. Look up MB1 and give Mike a call. Being that he wrenched on Factory Honda's for years he knows Showas inside and out. He just did my wifes bike for desert (not his expertise) and it was perfect for her. Not to stiff, not too plush...just right. He's in Ca so the turn around may be a little longer. Hope this helps. Good luck with the build.

This is the most recent pic I have of the bike.




-Kevin-

[2strokesurvivor]

Well about the preference. I live in the Dallas area and rode at a track called motoxpit. The track is usually well groomed with fairly soft dirt. I would like to consider myself an experienced beginner, and would like to have a bike with power and suspension to be able to ride fast and aggressive(who wouldn't). Thanks for the contact info for the engine and suspension..I will contact and see what they recommend. Is Eric Gorr on this site? Nice pic..

[KKXR400R]

Here's his [Only registered and activated users can see links. ]. They should have everything as far price and turn around on there also.

-Kevin-

[2strokesurvivor]

Thanks, I sent him an email. I contacted the suspension shop you recommended also...I'm excited to get the 'ball rollin'. This is the last time I was out before my daughter arrived. BTW I have heard that the carb on the 2003 is a dog and should be changed out for earlier (2000 or earlier) models. Is this true, and if so where can I find the carb?

[KKXR400R]

Thanks, I sent him an email. I contacted the suspension shop you recommended also...I'm excited to get the 'ball rollin'. This is the last time I was out before my daughter arrived. BTW I have heard that the carb on the 2003 is a dog and should be changed out for earlier (2000 or earlier) models. Is this true, and if so where can I find the carb?

Mike and his wife are good people. When Tracy went from MX to desert he revalved and resprung her bike for the cost of rebuild. We received 5 calls from them making sure everything was working the way she liked it. He was very persistent on making sure she was happy.

I'm not sure if it applies to the 03 but I made the switch to the 2000 carb on my 01 about 2 months ago. It's much crisper on the low end and pulls better in the mid. The 03's have a way different motor then the 01's so you may want to research the carb change a little before you commit to buying the carb.. Service Honda sells it for around $170-180. It gonna be pricer if you go through a dealer, so keep that in mind.


-Kevin-

[2strokesurvivor]

Yea I just received an email from mb1 (melissa). That was a quick response and they said I should be ok with the stock springs, just a revalve and set-up. I just read the thread on the 40+ rider who is in the hospital with the crushed vertebrae and it shakes my confidence on wanting to get back into the sport now that I have a child....I guess that is why I don't race. Maybe I just need to get off the MX..but flying is so much fun. I will check on the carb with some local small shops that I know and trust.

[ktm_cody_199]

Not sure how much a new/used carb cost but with the help of ,I have had GREAT luck with my JD jet kit.For the cheapest way to get the most out of what you have,there is no other way to go.I have also heard great things about the power-now and power-now plus.If you got a full fmf system,I believe fmf sells a powerup jet kit to mach there exhaust as well.O and what ever KKXR says he is right,helped me with my jetting.Dont forget to take a scotch-brite pad to your frame so it blinds everyone that looks at it or for an even better shine,rubbing compound and a rag or buffer.

[KKXR400R]

Originally Posted by ktm_cody_199

If you got a full fmf system,I believe fmf sells a powerup jet kit to mach there exhaust as well

Used the FMF kits and absoltely HATED it! The used some weird adapter for the main jet cause their jets have a different thread. I tried every combo in their little kit, including using stock needles to get Tracys bike running right but it just wasn't happening. I ended up tossing them and going to stock jets. Got her running like a champ. I would stay strictly with stock jets. Just my 2 pennies....

-Kevin-

[2strokesurvivor]

Well now I have another dilemma. I found the following bike on craigslist for approx $2000, and the bike looks to be in great condition with a lot of the work I wanted already done...and I would have a spare parts bike same yr/model. Any thoughts about this???

2003 CR250 Two Stroke in great condition. I switched to a 250f. Rebuilt top end, brakes and graphics/plastics with only about 3 hours. Bike has the following:

One Industries Snow Camo Graphics, Rebuilt top end with Wiseco piston and rings, Rebuilt forks, .45 springs (~190lb rider), New Brake rotors and Honda Pads, Oversize handlebars, ASV folding levers, O-Ring chain, FMF Fatty Pipe and muffler, Almost new Bridgestone M404 and M403 tires, JD Jetting Kit, GPR steering stabilizer (needs rebuilt $45 from GPR), Oversize tank and 5.1 shock spring not installed, but included,

[B_Rad]

Having rebuilt my bike twice now I would say you are defiantly going to save some coin buying a bike with the mods you want to do already done.
The carb you want is a Keihin 38mm PWK Airstriker. I had a JD jetting kit and somehow managed to bend both the supplied needles.(the reason I had to do a second rebuild) Have since gone back to the stock needle with the main and pilot as suggested by JD and the difference is not noticeable at all.
Good luck with the overhaul or the new bike, whatever way you go.

[2strokesurvivor]

Thanks B RAD,

I am going to contact the owner and try to set a meeting at a local track so that I can ride some laps on the bike...but seeing as I have not been on a track for over a year, I really won't be able to push the bike hard. I'll just have to try to make sure it sounds and feels mechanically sound. Any suggestions on what to look for on a rebuild to make sure it is done properly?

[MXracer21]

LOSE THE BLACK PLASTIC would be my first step! haha In all seriousness, i would probably re-do the top end, regrease linkage, wheels, etc. Give everything a good cleaning. ANd then i would make mine look like one of the factory Honda Cr 250s from a few years ago. V-Force reeds, and maybe a Pro circuit exhaust system would give your bike some more power. Also, be sure to check the tension of the cables for the Electronic cable-actuated power valve. If you are unsure how to do this, there are many tutorials around the net.


Go with the new bike if your budget allows it. Its going to be awesome having a spare bike.

[ktm_cody_199]

Originally Posted by KKXR400R

Used the FMF kits and absoltely HATED it!

-Kevin-

They really that horrible?Glad I got the JD kit,almost bought the fmf kit because it came with more stuff