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  #1  
Old 03-14-2014, 11:52 AM
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Default Race prep-2006 CR 250....

     

Just before race season here and about to get started on race prep for cousins CR250, which is mostly stock, besides the following:
-pro-circuit system-jetted correctly
-V-force reeds
-red rims
-bling bits ( levers/pegs etc )

Not only is this race prep for the new season but I guess also a bit of a restoration ( which I use lightly as the bike is already a BEAST! )
Pretty much everything will be serviced / modded / etc

Here is the list so far ...........

MOTOR:
-new internals-bearings seals etc
-cases blasted
-new piston etc
-new clutch
-possibly polished transmission
-new crank
-bling factor ( ) -you go faster with bling-------
Of corse the whole engine is getting our full attention checking everything is 110% for race season.

BRAKES:
-new pads
-new rotors
-braided lines
The master and calipers are in good shape so fresh fluid and good to go.

WHEELS:
-potentially new hubs and rims ( still looking at options )

FRAME:
-minor repairs
-clean and inspect for damage
-super good clean and partial polish ( ) -because shiny goes faster-----

SWING ARM:
-polish
-new bearings etc

SUSPENSION:
-re-valving
-new springs front and rear to suit rider weight
-complete new internals shock and forks
-new linkage bearings and just about every other bearing you can think of will be replaced

APPEAL:
-new seat cover
-new plastics and graphics ( might be a bit later )
-aftermarket bling factor-chain sliders, bash plate, footpegs, covers, chain adjusters, brake and clutch, levers, bars.... The list true lot is endless.......


In short this will be nothing short of a half heated job!! Really looking forward to putting some hard hours into getting bike ready for cousins race season, it's going to be awesome when finished and I can't wait to start tomorrow.

Pictures tell a better story and once daylight breaks I'll picture up parts and the bike etc!!







Let the fun begin......
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Old 03-14-2014, 12:28 PM
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Sounds like fun! So your cousin's the rider and you're the mechanic
on this team?

dogger
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Old 03-14-2014, 12:31 PM
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Fun indeed!!! Yea I guess you could say that although my cousin also wrenches on bikes.
I'm pretty sure the parts orders have been coming in for a few months now...
There is so much I'm forgetting thinking about it....
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Old 03-14-2014, 01:00 PM
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I just want to know who the "sponsor" is so I can get some gear for my bike!
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Old 03-14-2014, 01:54 PM
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Really looking forward to this since I have an '05. That way I'll know what it should look like.
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Old 03-15-2014, 01:34 AM
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Some before shot in the garage.



















We made a start and got the bike down to its chassis. Nothing too exciting, but will get some progress pictures soon.
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Old 03-15-2014, 09:19 AM
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Some thoughts and recommendations:

First thing you need to add is a pair of radiator guards. One well placed
rock and you're done. I'm also not a big fan of pointy objects in the rider's
compartment, that vent "spike" looks painful. I recommend you run that
brake snake at more of a 90 degree angle to the brake lever (I use the
engine mount).



The way you have it now will not save the brake lever from anything but
falling off after it's bent to an unusable angle.

In another "timely" coincidence, MXA has an article in the April edition about
race prepping a gen 3 CR250. Probably has some useful info. Lastly,
mxgirl175 just finished prepping and is racing one of these - another good
source of current info.

All I can add from my years racing these bikes is keep an eye on the PV cables,
(they like to come loose), and the electric PV motor is problematic (corrosion,
rust). The airbox is a poor design and will leak in dirt without some billet
pieces and strategic use of RTV. Engine responds well to a PWK and VForce.
Best pipe for MX is a Bills. If you dump about $1000 in port and headwork, it
will make as much power as a stock 2000-01. Pretty good stock suspension.
Best Aluminum CR frame. Good Honda build quality and reliability.

Good luck with the project and the coming race season, looks like a lot of fun.

dogger
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Old 03-15-2014, 03:28 PM
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Hey Dogger!

Thanks for the replies and advice it's much appreciated!! Will definitely take your advice on a few matters.
Here are a few replies:
Quote:
add is a pair of radiator guards
For some reason the PO never had guards on...(???)... Yea go figure. I'm pretty sure new radiators are on the cards. We have OE guards already and Works braces.
Quote:
that vent "spike" looks painful
I'm not either! I prefer the vent line... While this is flex-able it could hurt, I'll forward the suggestion.
Quote:
brake snake at more of a 90 degree angle to the brake lever (I use the engine mount).
Great idea, I'll change that over on reassembly. We weren't sure how it ran when we put it on first time round...
Quote:
keep an eye on the PV cables
Will do! Any suggestion tho?
Quote:
the electric PV motor is problematic
Not a fan of the RC PV for this reason, just another electrical thing to break...
Any suggestion on keep these in good shape? Besides replacing it?
Quote:
The airbox is a poor design and will leak in dirt
I believe this was taken care of, for peace if mind we'll check over it and maybe put in a fresh seal.
Quote:
Engine responds well to a PWK and VForce
The 'Stock' carb has had some work done to it... It is on song with the Pro-C pipe... Jetted to the T, it's an arm breaker!! However... We do have one if these, just lying around.....





As for now with the basically stock motor it's enough power I think... We'll leave the port and head work for later...

Quote:
Best pipe for MX is a Bills
I think a new pipe is one the cards at some point. The current one has nasty dent ( not visible if your just look at the bike-it's underneath ) so a replacement isn't far away.


Quote:
Good Honda build quality and reliability
Couldn't agree more!! And with OE parts so reasonable it's a dream to buy replacements!!
Lots of aftermarket support too.

Hoping to get the parts....many....parts.... Pictured up, along with the progress so far. Cleaning and sending various parts out soon.

Keep a look out for updates
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Old 03-16-2014, 10:51 PM
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Quote:
Originally Posted by dogger315 View Post
Engine responds well to a PWK and VForce.
Best pipe for MX is a Bills. If you dump about $1000 in port and headwork, it
will make as much power as a stock 2000-01.

dogger
If one spends $1000 to make their 47hp 06 into a 45hp 01 they should ask for their money back. Pro-circuit can do both the head and cylinder for $380 and if you go with the head cut for race gas they claim 53hp. I owned a 92,94 and rode my friends 01 extensively and while they have a nice spread of power they're definately slower. I don't miss them at all.
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Old 03-16-2014, 11:08 PM
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Power isn't the game here thankfully.....
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Old 03-17-2014, 10:00 AM
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As long as you're aware of the PV cable problem and make it part of your
regular maintenance checks, you should be OK. As for the PV motor, check
it out. If it looks good, spray some CRC on it and keep an eye out for rust
and corrosion. If you start having problems, replace it and do the same for
the new one. Also, pull the cover after every wash and blast the motor and
cavity with compressed air, then coat it and recover.

If you have the TMX dialed in, go with it. If you can keep that TMX dialed
in throughout the season, you're my hero.

dogger
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Old 03-19-2014, 04:50 AM
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So got the bike down and started on the motor, just some after work tinkering



We open the motor over a drain vowel to catch the oil that doesn't come out the drain hole.



A bit of blow by on that piston (???)



Quite a bit of slurry in the bottom? Hmmmm



Haven't gotten too far just yet....



Hope to split cases soon and get cracking cleaning and inspecting everything, with the oil condition I'm wondering what the tranny looks like. No metal particles just very metallic-looking??
I guess this is why we do this sort of thing
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Old 03-20-2014, 01:13 PM
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Quick update, got the cases split and cleaned up ready for aqua blast. Pictures to follow later
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Old 03-21-2014, 01:20 AM
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Here are a few pics nothing exciting....



Here's a handy tip, you can use a cable tie/zip tie OR you can you an O-Ring to stop the gears from floating around. Remember to check for the thrust washers...they have the tendancy to stick to the bearing inners............



Got the tub ready with parts for aqua blasting, a few more than usual
This build is getting tip top service



Later tonight we'll get the tub ready with the parts for zinc and maybe start cleaning up things that aren't getting replaced, probably start cleaning the engine components and getting all that ready for when the cases come back....

Oh and change the carb on the Rm 125 what a night
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Old 04-01-2014, 07:54 AM
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Default Engine case and hardware update.

Got the cases and other bits after aqua blast and man they look great!!!!!

I'm very excited to put some fresh internals in these cases!!

I think they look better than the previous cases as these had less neglect ....

Subframe



Triples





Cylinder and head





Linkages





Cases











---------- Post added at 12:24 AM ---------- Previous post was at 12:19 AM ----------

Hardware









Chose the gold plate for a change came out really well!!!!

Frame is currently in for a weld repair ( gash in the undercarriage needing attention )

New wheels are on there way and a few other bits ( plastics etc )
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Old 04-01-2014, 11:48 AM
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Wow! That new engine bling looks beautiful! I cant wait to see it all buttoned up, that will look pretty freakin cool!
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Old 04-03-2014, 02:50 PM
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what is aqua blast? I want some...
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Old 04-03-2014, 04:05 PM
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It's high pressure water with glass media. It's a lot better for aluminum and such.
Aqua Blast Cambridge - Aqua/Vapor blasting services throughout Cambridgeshire
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Old 04-04-2014, 04:58 PM
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do you have one of these or did you send them out for it?
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Old 04-14-2014, 08:35 AM
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Looking at a setup for my 'hobby job'...
Got stuck into the forks/shock/engine...
Engine has new bearings and waiting on more parts.

Here are the cases at least...





.....

No other exciting pictures just yet.....
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