Author Topic: 88 XC my first trx250r (Read 21382 times)

dem3500 · « **on:** December 27, 2014, 07:16:03 PM »

hey guys! one of your members here suggested that i bring my build over here. so here i am! it appears this is where all the cool kids hang out anyway lol. before i start i want to get something straight......i am not affiliated with any company and will not try to sell anyone anything. now with that said, i do do all my own PC work, and i LOVE to show off my work! so not that i got that off my chest lets begin...........................i got an itch to start XC racing. dont ask me why, but i did lol and a banshee wasnt going to cut it!

this is what i started with. not running right, $1700. couldnt pass it up!

dem3500 · « **Reply #1 on:** December 27, 2014, 07:18:35 PM »

it had some goodies to say the least!!

I forgot about the brand new CBR radiator

dem3500 · « **Reply #2 on:** December 27, 2014, 07:19:09 PM »

After I got it I noticed it had a pump gas dome. I bought a race gas dome for it and installed it. It didnt seem to have near the power i thought a race gas 110 should have. I did a comp test and I was right haha! Only 100psi. Yes that would do it! I got the engine bored, 2 sizes over and spent a small fortune on the ESR piston and was back in action. The guy that did the bore said it looked like it had been run for a long time worn out and that was probably why the cyl was beat up so much and needed to go 2 sizes over. Who knows lol. Its back running right, that's l I really care about

I picked up a set of stage 3's
And a set of 4-1 reinforced front wheels.
That in itself was a pretty bad ordeal and I kind of lost my ass in that deal. I waited over a month before I messed with the front wheels and found out they were NOT 4-1's like I was told! Oh well. You win some and you loose some. In the end I decided to keep and run the shocks. They need redone so I will send them out some time in the next few weeks.

dem3500 · « **Reply #3 on:** December 27, 2014, 07:20:03 PM »

The weekend after I got the engine together I went riding with my two girls (14 and 10). I went off a small jump and my throttle stuck.....wide open! Yea that didn't end well! And the worst part about it was that nobody saw it! Haha. I think the quad might have done a back flip! Ha I hit the ground pretty hard.

I drove it back to then parking lot with a nice headache and only 3 turning wheels haha

dem3500 · « **Reply #4 on:** December 27, 2014, 07:21:35 PM »

So I had plenty of bent and broke stuff but that's the name of the game so I decided to upgrade the spindles and brakes. I got a set of 450r spindles, brakes, and LSR billet hubs. I also broke the rear grab bar off and bent the front bumper. I rewelded the front bumper where it cracked from pulling it back straight. I also rewelded the grab bar but decided to go a different route. My garbage mad buddy found this grab bar in the trash. It didn't fit so I cut it all apart and rewelded it to fit. Yes....I weld a lot of stuff! I enjoy welding haha. I find every excuse I can to weld something. I also finally decided on a color. I did not want a red frame and I didn't really want to strip the red anodizing on all the nice ESR parts. I finally decided on goldtastic from prismatic powders. I do all my own powder coating. Same with the welding, I PC just about everything I can get my hands on! Haha.

This is a better pic of the gold. Synthetic light sucks for a lot of cors especially metallics.

dem3500 · « **Reply #5 on:** December 27, 2014, 07:22:08 PM »

The frame is going to be gold with a clear coat, same as the bumper and grab bar. The nerfs, wheels, and upper arms are going to be black with a gold pearl clear coat. I donr have anything sprayed with the black yet.
I think I'm pretty much cought up to this week at least.

dem3500 · « **Reply #6 on:** December 27, 2014, 07:24:02 PM »

and here is where the real fun begins!
I bought a set of Rath 450r nerfs with heel guards. These things are made real well. I was surprised about the quality. Very nice for sure. They took a little more work than I expected to get fitted but was all good in the end. dont mind the crappy white PC. that will all be taken care of!

I cut off the existing peg mount

dem3500 · « **Reply #7 on:** December 27, 2014, 07:25:20 PM »

1" od tube is what would fit in the nerfs. I ended up grabbing some 3/4" black pipe from the hardware store. It was a little bit bigger than 1" but some time with the flapper wheel I got it down so it would fit the nerfs. Getting it to fit through the frame was a little bit harder. There's a reinforcing sleeve inside on both side. (im sure most of you all know this already lol....im new! leave me alone haha) All I did was spend some time with the die grinder so I could slide the pipe through. Not difficult but took a bit of time to finish.

dem3500 · « **Reply #8 on:** December 27, 2014, 07:27:01 PM »

A pic of the sleeve on the left side. The right side sleeve was a little bit deeper.

dem3500 · « **Reply #9 on:** December 27, 2014, 07:27:47 PM »

BAM! and there it is!

Got the front mount in as well

All done aside from final welding.

dem3500 · « **Reply #10 on:** December 27, 2014, 07:31:44 PM »

dont mind my cluttered garage. its not normally like that! too many projects not enough time or space! hahaha

dem3500 · « **Reply #11 on:** December 27, 2014, 07:35:08 PM »

and to carry on with the heel guards.............
They lined up close, but not quite lol

Trimmed off the resivour bracket

I cut off the original mounting tab and drilled a hole big enough to fit over one of the mounts for the rear master cylinder

Got it tacked together

dem3500 · « **Reply #12 on:** December 27, 2014, 07:37:30 PM »

I made lots of progress today. I finished tearing down the the bare frame despite the frozen swing arm bolt. A bit of heat and some patients did the job. I was about to cut it until I saw the price of a new one lol. I took a half hour and got it out in one piece.

While I was waiting for the swingarm to cool back down I did some repairing and beefing up of the upper motor mount. It was almost cracked all the way around on one end. I didn't like the small welds holding the tabs on so I added some of my own.

I wanted the tab to be welded all the way around also

dem3500 · « **Reply #13 on:** December 27, 2014, 07:39:07 PM »

I wanted to get all the welding I could done. I can't get my frame to the sand blaster till next week.
I wanted to beef up where the heel guards attache to the rear sub. I didnt want to pinch the hollow tube with a bolt so I took some 1/2" solid round bar and drilled a small center hole through and welded it through the frame. That should work for some beefy mounts!

dem3500 · « **Reply #14 on:** December 27, 2014, 07:42:11 PM »

got the nerf pegs finished welded