My 88 stock frame rebuild/cleanup

[Bowtie316]

I am getting far enough along to start sharing the progress on this, so I though I would start a thread.  Basically what I have going on is I had an 88 that was in good shape mechanically but had sat outside or something and was pretty ragged to look at.  Plastic was beat, seat was beat, etc.  This started out as a stock rebuild but like many other projects has morphed into something else.  Now this is no high end, high dollar build by any means, I am re-using many of the stock parts after cleaning them up.  Really just want to make a nice bike to keep for clean rides, and duning.

This is what it looked like a couple weeks back.




This was dissassembly and mocking up LSR +2 arms and measuring for shock lengths and such.


I took it down to the frame, installed Pumashine gussets.  Also had a little frame repair to do.


 Got the frame back from powder last night, I should be able to start getting pictures uploaded tonight.  Going to thrash on it this weekend so I should have some updates over the weekend too.

[Bowtie316]

You mean the arms that you hosed me over on buying? The ones that I missed by just a little bit cuz I work thirds and was sleeping when they got posted? LOL just kidding man. I love projects and will keep checking this one out!

Yes I think those are the ones, got one arm re-chromed, and had to buy one ball joint and a bushing sleeve but they're complete now.

Here is the frame back from powder.


Pumashine gusset kit installed, I didn't use all the parts.


Dirty spindles and bolts, old shocks etc. I have to measure for new shocks so I'm assembling this way for now, will clean everything up when the shocks are on the way.


New stem bearing, used LSR stem.


Powdered rear spring as well, not sure if I like it.  I will probably send this oem rear shock out for rebuild/revalve this winter.


The laker plastic is not going to work for what I want to do.  Too bad I already cut it up to mount the 88 hood.  



That's all I got for now, I have some riding to do.

Oh yeah, and I got a bit box of parts from ESR that should help this thing out a bunch.

[jamieg45]

To measure for your front shocks and get your rear redone have S.F. Racing do it and get a set of nice pep fronts, he will ask you to measure your lower a-arm from the center of the bolt hole on the frame to the center of the bolt hole where the shock mounts and that will determine your shock length.

[jamieg45]

He did them for me on my lsr and did the pep rebuild to the stock 88-89 rear shock and that thing rides very nice.

[Bowtie316]

I already measured lengths extended and compressed before I pulled it apart, but in order to get the HLS shocks I want, I have to give them some more info before I can order.

I should have some more pictures tomorrow, I have a motor to put together.

[Bowtie316]

This is what I did today, had to swap a stock stroke crank into the motor I had that was clearance for a 330. Got the ESR 330 cylinder yesterday, port timing is much better than the last one with the 4 mil stroke. Got it all assembled, leak down test passed with flying colors so I dropped it in the frame. Here are some pictures.

Bottom of all the ports line up with the piston at BDC like they are supposed to.


This is just a trx7 port match so it isn't too smooth.






Coolant passage above the exhaust is milled way down deep in the coolant passage.  My last one wasn't this way, this should help with hot spots and seizures.


Drilling the lube holes in the piston.


Finally in, the chain wax is hard to get off, need to find a better cleaner.

[Bowtie316]

Slowly making progress. Seat cover and rear carrier showed up, but was stuck at parade and fair last night.

CBR radiator, Roll pegs, wire harness, CDI, regulator, 38A/S, and Alba bumper installed.

[JesseA420]

lube holes? are you drilling those all the way through the skirt so oil can splash up under and through them to the outside of the skirt while its traveling?

[Tbone07]

Do you need to drill the lube holes of you don't have a bridged exhaust port?

[Bowtie316]

lube holes? are you drilling those all the way through the skirt so oil can splash up under and through them to the outside of the skirt while its traveling?

Yes, they are drilled all the way through.  The pistons come with a hole started for both styles of cylinder, bridge in the middle or two for the auxilary exhaust ports.  I drill the ones that line up with the bridge to help lube and cool it.  Something I read somewhere that I really don't know anything about.  I posted the picture too see if there were any comments about it.

[Bowtie316]

Do you need to drill the lube holes of you don't have a bridged exhaust port?

No I don't see a reason. This one is drilled in the two outer sets of holes that line up with the bridge between main exhaust port and auxiliaries.

[Bowtie316]

I have been making a little progress here and there, but not much to show yet.

Had to show eddie some love.


Bumper spacers worked nice, 400ex bumper on 250r. Thanks [MENTION=9]Pumashine[/MENTION] for telling me where to get them!

[Bowtie316]

Got it mostly done and went to Little Sahara last weekend, the bike ran awesome, GT shocks were great, ESR 330 was great and faster than I thought it would be. Not much left to do now but send the seat to jettrim to get the cover to fit right, and change the back bumper. And I'll probably get some original style stickers for it instead of the machine head graphics.  I'll have a video up too before long.

[Bowtie316]

Do share where you can get them spacers. Thanks. Btw the bike looks sweet

Thanks Jon, here is the thread we discussed the spacers, http://trx250r.org/threads/4040-Bolt-spacers-or-sleeves-or-barrels-or-whatever-you-call-them, but you can get them from www.aluminumspacers.com.  I wasn't sure about posting links to non=sponsor websites but since you asked.

[Bowtie316]

posting links to any vendor is acceptable from a member, the problem arises when the vendor themselves does the advertising

Ok thanks I understand. I always just try to play it safe, it's easier than reading the rules.