Author Topic: My '86 project after a LONG vacay from 250R's! (Read 17877 times)

Jimbo45 · « **Reply #30 on:** February 19, 2015, 09:03:31 PM »

Thanks! I am not done quite yet.
I did get some cold weather tuning done today. For frigid, 10 degree weather, the DGG needle in the fourth notch, and the #40 pilot @ 1-1/4 out, and a #162-160 main, seem to be about perfect!

Jimbo45 · « **Reply #31 on:** February 27, 2015, 11:30:50 PM »

New bumper and new front master cyl

Old bumper:

New bumper:

Jimbo45 · « **Reply #32 on:** March 19, 2015, 08:01:44 PM »

I reworked the chopped up race harness, and fixed it to add an OEM kill/light switch, tail light and head light, and a voltage regulator. Completed my self made new wiring harness, with new factory connectors! Also, got the '88-'89 style hood and light mocked up, while waiting on the headlight rubber bushings.......it lights up great!

red88r · « **Reply #33 on:** March 19, 2015, 09:04:49 PM »

I like the red/black combo on this. Looks like a nice rebuild!

Jimbo45 · « **Reply #34 on:** March 19, 2015, 09:53:34 PM »

Quote from: red88r;51861

I like the red/black combo on this. Looks like a nice rebuild!

Thanks! Its actually Orange/black, but its hard to tell with my crappy flourescent lighting in the pics. I need to get it outside as soon as the weather permits. You can see the rain in the background I think, lol.

Jimbo45 · « **Reply #35 on:** March 19, 2015, 09:58:33 PM »

That headlight hood is actually a new fighting red Maier hood, that I plasti dipped black, then put like 6 coats of glossifier on. I hope to get red plastics some day, and peel that plasti dip off! Looks good for now, though! lol

red88r · « **Reply #36 on:** March 19, 2015, 10:48:12 PM »

Oh my bad...even better. I always wanted to do one with alot of black and then orange fullbores.

Jimbo45 · « **Reply #37 on:** March 26, 2015, 09:02:12 PM »

Got my headlight built with a mix of oem parts and collars from the hardware store! Ready to bolt on and plug in. I do have the long screw adjustment hardware, but need to add a tab to this 300ex light, for it to work. I dunno, might not even do that, it seems fairly solid without it.

JesseA420 · « **Reply #38 on:** March 26, 2015, 09:42:41 PM »

nice jim, where did you get those decals? i see them on many bikes, never seen where they come from before though. my bike when i bought it even had them on it lol.

Jimbo45 · « **Reply #39 on:** March 26, 2015, 10:39:20 PM »

Quote from: JesseA420;52229

nice jim, where did you get those decals? i see them on many bikes, never seen where they come from before though. my bike when i bought it even had them on it lol.

Here:

http://www.ebay.com/itm/Stickers-Decals-Graphics-For-TRX250R-TRX-250-R-250R-Fender-Hood-Plastics-Tank-/321426535053?var=&hash=item4ad683b28d&vxp=mtr

Jimbo45 · « **Reply #40 on:** March 28, 2015, 12:36:05 AM »

I decided to go ahead a put an adjustment tab on this 300ex headlight, since I had the screw, washer, spring and nut. I just fabbed a 90 degree piece of aluminum and drilled some holes, and JB welded it to the light. Should work out great and I will install it once its cured.

Jimbo45 · « **Reply #41 on:** March 30, 2015, 08:59:59 PM »

Hey guys, put the new top end on last night. Quick advise before I button it all the way up...........

I have a short rod motor, and this cylinder that CT did, has been resurfaced/decked. I first put it together with just one cometic .020" base gasket, and looked to the piston height at TDC. It looked like the edge of the piston was about even with the deck. That had me a little concerned on squish clearance. So, I put a second .020" cometic base gasket, and it appears the piston is now about .020" below the top, with two base gaskets on there (estimating). I am sure it would have worked out with just the one base gasket, since CT did this cyl and head and they provided the gasket set. But, I think I will run the two base gaskets, to be on the safe side, and especially since I am not after max horsepower anyway, and will be running Pump/race gas mix.

My concern is the change to port timing, since I raised the cyl .020" over stock. Is that a big deal? Should I not run the two base gaskets, and instead just put one in and do a solder squish test? (Problem is, I already torqued the head down, and not sure I can reuse the layer head gasket again).

Here is a pic of the piston height with two base gaskets......

Pumashine · « **Reply #42 on:** March 30, 2015, 09:31:03 PM »

Looks fine if you are using the standard .078" or 2mm head gasket. If you use 2 base gaskets you should have put some sealer on there. Base gaskets are available in many different thicknesses so you only have to use one without worrying about leaks.

Jimbo45 · « **Reply #43 on:** March 30, 2015, 10:15:04 PM »

The head gasket is a .040" Cometic 3 layer gasket.

mandom250r · « **Reply #44 on:** March 30, 2015, 10:20:04 PM »

looks good to me