Categories
Honda MX Restoration

1986 Honda CR 125R dirt bike restoration

Project – https://www.vitalmx.com/forums/Old-School-Moto,22/Project-bike-1986-Honda-CR125R,1299309

Parts:

  • new clutch cover
  • new fuel tank
  • restored plastic by sanding, heat gun treatment and Plastic Renew stuff
  • HRC cylinder
  • rebuilt crankshaft (new used) with a 50mm stroke
  • new fork seals, clutch/throttle cable, chain and rear sprocket
  • new seat cover
  • piston with one ring
  • Keihin 36mm
  • Yamaha footpegs
  • IMS shift lever
  • custom pipe hanger
  • Motion Pro throttle assembly
  • front brake system from last generation CR125/250
  • Shock mud guard is brand new part for 1990 CR125
Categories
Honda MX Restoration Supermoto

Honda CR 500af supermoto build (CR 500 + CRF 450)

Project – https://www.supermotojunkie.com/threads/project-black-diamond-cr-500af-street-build.109288/

donor bikes – 91 CR500 and 07 CRF 450

Engine

  • 91 cr500 engine stripped and vapour blasted
  • rebuilt and balanced crank with prox conrod
  • all new bearings and seals
  • stan stephens moderately tuned barrel with oversize prox piston 502cc
  • pro designs polished billet coolhead with multi compression inserts
  • boyesen radvalve and block carbon reeds
  • talon clutch basket/ebc drc clutch with standard springs
  • boyesen clutch cover
  • boyesen ignition cover
  • pwk carb
  • polished engine parts/head/kickstart/waterpump cover/coolhead/ carb/engine bolts etc
  • wrinkle paint finish to casings and barrel
  • samco engine hoses
  • silicone carb hoses
  • modified crf radiators
  • cr 250 airboot with custom airbox plate
  • new crf 450 airbox and standard filter
  • high output coil.
  • 07 crf 450 frame
  • pro fabricated to fit cr 500engine, powdercoated graphite
  • aprillia rxv swingarm,powdercoated graphite
  • modified subframe powder coated graphite
  • costom made billet headstay
  • marzzochi shiver 50 forks pro-action setup marzzochi triple clamps
  • ohlins ttx rear shock
  • polished crf shock linkage
  • ohlins 2.1 steering damper
  • all bearings replaced/headstock/swingarm etc
  • trail-tech sidestand
  • pro-circuit platinum expansion chamber with crf 250 carbon/titanium akropovic twin cans
  • goldspeed carbon wheels with polished hubs
  • goldspeed ultra road legal tyres
  • beringer radial caliper/factory polished
  • beringer master cylinder/factory polished
  • beringer clutch lever/factory polished
  • beringer front disk
  • aprillia rxv rear brake
  • pro-carbon fuel tank
  • pro-carbon tank shrouds
  • pro-carbon front fender/shortened and modified
  • pro-carbon frame guards
  • carbon wrapped rear fender
  • crf 450 sidepanels
  • new honda rad guards
  • driven racing carbon bars
  • infinity carbon handguard sheilds with cycra probend handguards
  • icon racing billet fuel cap/polished
  • sdg step seat
  • GFX designs custom graphics
Categories
Honda MX Restoration

1989 Honda CR 250 rebuild

Bike was listed as “locked up”, but very low hr bike. Pretty much everything was original except FMF pipe and silencer and bike was stored inside.

The last time it was ridden it sucked in dirt. Crank was sent to Ken Oconner for rebuild.

In seizure cylinder wasn’t damaged but plating was flaking pretty bad. Cylinder with Pro X cast piston was sent to Powersealusa.

The chassis on the bike was clean and original. Just a good cleaning and regreasing. Shock bumper was missing, so it was dropped off for a rebuild.

Carb had 58 pilot and 178 main. Previous owner also had a reed spacer on the intake with an FMF gnarley pipe.

For Racetech fork springs owner had to make make a pvc spacer as the new springs are 40mm shorter than originals, stock springs had a lot of preload on them, owner went with a lot less at the RaceTech recommended 4mm preload.

Parts

  • Pro X rod kit
  • replaced all bearings and seals
  • new seat
  • Boyesen reeds
  • yzf pegs
  • SFF forks
  • Excel rims
  • PC raw pipe
  • OEM clutch cable and intake bolts
  • Works Connection frame guards
  • Racetech fork springs
Categories
Restoration Supermoto

2005 Kawasaki KLX 300 supermoto

The KLX may not be the biggest, baddest, best sumo out there, but its sure a hell of a lot of fun.

There is room for improvement in some things, which were addressed with rebuild. First and foremost is the suspension (front sprung for 155lb rider, rear sprung for 180lb rider, im 195 w/o gear). New suspension will be sent off and resprung and set up for my weight and motarding along with the shock refresh.

Also owner disliked the sluggish way the vacuum operated stock carb supplies power so it was changed out for a Mikuni 36MM pumper carb. the Carb also complimented the 351cc big bore kit from Bill Blue.

Project page – https://www.supermotojunkie.com/showthread.php?124050-Modernizing-my-2005-KLX-300-Supermoto

Part list:

  • Powder coat frame, swing arm, engine mounts and skid plate Satin Black.
  • New bearings in steering head, swing arm, and suspension knuckle
  • 1994 KX 125 forks
  • Rebuilt suspension with proper springs for my weight
  • Anodized Fork tubes black
  • Custom machined spacers for ride height and axle
  • Powder coated shock spring Green
  • B&B 351cc Cylinder kit
  • Mikuni TM-36-68 Carburetor
  • MotionPro Vortex throttle
  • MotionPro Throttle Cable (Custom specs, 4″ longer, connector to mate with Vortex throttle)
  • Custom SS brake line (Russell components)
  • EBC Dirt Racers clutch kit with springs.
  • Green radiator hoses.
  • Renthal sprockets (15t/48t)
  • DID o-ring chain
  • Renthal Fatbar (CR High)
  • Renthal Grips (Med)
  • 2009 KLX250sf headlight (Custom fitted)
  • 2009 KLX250s headlight shrouds (Green and white)
  • CRG barend mirror
  • TrailTech Vapor
  • Moose Skidplate
  • Wide pegs
  • Moose shift lever
  • eBay Taillight from china.
  • 2010 Ninja 250R master cylinder
  • eBay levers for 250R from china
  • 2010 KLX250sf rear brake caliper (black)
  • EXCEL rims
Categories
MX Restoration

1992 Kawasaki KX 500 restoration and repair

Project – https://www.vitalmx.com/forums/Bike-Builds,46/1994-KX500,1327425

General specification:

  • Engine Displacement – 499
  • Engine Type – liquid-cooled, two-stroke
  • Cylinders – 1
  • Horse Power – 62
  • Transmission – 5-speed
  • Torque – 64.7 N-m 16.6 kg-m. 47.7 ft-Ib) @6000 RPM
  • Dry Weight kg – 100
  • Fuel Tank (gal) – 2.6
  • Fuel Tank (liter) – 9.9
  • Oil type – 10W/40
  • Front Tire – 80/100 R21
  • Rear Tire – 110/90 R19
  • Wheelbase – 1491mm (58.7in)
  • Wheel travel Front – 300mm
  • Wheele travel Rear – 330mm
  • Overall length – 2200mm
  • Overall width – 815mm
  • Overall height – 1205mm

This 1992 Kawasaki KX 500 was long coming project, because owner were looking for right motorcycle over year till this gem poped up. The goal was to update the brakes, wheels, suspension, clutch and all around fit and finish. And end result speak for it self.

Parts:

  • 2011 Kawasaki triple trees got the stem pressed out and the KX500 stem pressed in
  • changed fork stops
  • the Brembo brakes and wheels are off a 2013 KTM
  • EXCEL Rim
  • new impeller drive gear old on the end of the crank shaft was beat to death, mushroomed and had broken teeth
  • made bracket to utilize KX 450 sliders
  • custom made wheel spacers
  • 450 cover
  • rebuilt shock, race tech gold valve and bladder cap
  • hydraulic clutch
  • cerakoted engine – tungsten color
  • ported cylinder and cleaned up power valves
  • new clutch basket
  • seat cover from MotoSeat
  • resotred PRO Circuit pipe

Simple way to upgrade the clutch pull arm for a little more leverage. Take a yamaha 450 pull arm shaft and this billet arm thats a tad longer, weld the splines to your 500 arm.

Categories
MX Restoration

1979 Honda CR 250 restoration

Project –
https://www.vitalmx.com/forums/Bike-Builds,46/Turning-a-1979-CR250-barn-find-into-a-1978-RC250-replica,1343747?page=1

Looks like this bike was gently trail ridden for maybe 20 or 30 hours. The only wrench this bike ever saw was the rear axle nut to adjust the chain. It was pretty clear that the wheels had never been removed from the bike and the original “Claw” tires still had most of their tread left. The grips and levers looked almost the day they left the dealership.

Obvious that this bike not only had not been raced, but it doesn’t even look like the bike had ever been even in a small crash.

The paint on the fuel tank was unmarred and no sign of even the slightest knee scuff marks. The same goes for both unmarred engine covers. The seat still looked brand new, no cuts or scratches. Most bolts still looked quite new and the trans oils looked pretty good after sitting in a dry place for probably close to 40 years. There was a little bit of fading on the front fender, but other than that, the plastic all looked good.

There was no dry rot on any of the rubber parts either which were still supple like new. There were remnants of a mouse nest in the airbox, but this bike is pretty much a time capsule from the past. The few minor scratches on the swing arm and left side plate looked more from having things piled up against it in a garage than riding. This bike is 100% original.. no parts were broken or missing.

In the end the best match for the engine paint was the RAL 3020 Traffic Red form LVP.

For the slightly lighter colored frame, the Tahitian red from National Autobody & Paint Supply was a dead ringer except it only comes as a base coat which is a flat finish and needs a gloss clear coat.

Part list:

  • rear motor mount bracket fabbed by Ray Carlstedt
  • replica HRC bolts,
  • upper motor mount bracket,
  • RC-replica swing-arm spindles,
  • stainless RC replica motor mount bolts,
  • CNC exhaust flange that will prevent spooge dribble typical of the stock bike,
  • vintage D&G front fork air caps,
  • RC replica white gas cap,
  • VMX fenders,
  • heavier .48kg springs from Race Tech 15 weight oil,
  • shock guard to protect the shafts on the Fox Air Shox
Categories
MX Restoration

1996 Kawasaki KX 250 rebuild

Project – https://www.vitalmx.com/forums/Bike-Builds,46/96-KX250-hybrid,1336043

Part list:

  • motor is getting a full rebuild with oem crank
  • powdercoated frame
  • powdercoated subframe
  • black wheels
  • cerakote hubs
  • purple shock
  • new zinc plated bolts
  • 96 oem graphics seat cover from Evo mx
  • Pro Circuite pipe
  • new r304 silencer
  • 06 kx450 forks (rebuilt)
  • 07 kx450 wheels, hub, rotor
  • axles, spacers & 07 kx450f brake system
  • EBC 280 kit brake kit
  • evo 96 decal kit
  • custom carbon fiber skid plate

Motorcycle specification:

1996 Kawasaki KX 250 specification
Categories
MX Restoration

1992 Honda CR500R restoration

Specification for bike (CR500RN)

Dimensions
– Overall length – 2183 mm / 85,9 in
– Overall width – 825 mm / 32,5 in
– Overall height – 1240 mm / 48,8 in
– Seat height – 964 mm / 38,0 in
– Wheelbase – 1489 mm / 58,6 in
– Ground clearance – 343 mm / 13,5 in
– Dry weight – 101 kg / 222,7 lbs

Frame
– Type – Semi double-cradle (steel)
– Front suspension, travel – Inverted telescopic fork (adjustable) , 310 mm / 12,2 in
– Rear suspension, travel – Swingarm Pro-link with mono-shock (adjustable), 320 mm / 12,6 in
– Front tire size – 80/100-21 51M
– Rear tire size – 110/100-18 64M
– Front brake – Single disc, 2-piston caliper
– Rear brake – Single disc, 1-piston caliper
– Fuel capacity – 9,0 l / 2,38 US gal
– Trail – 119 mm / 4,7 in

Engine
– Type – Water-cooled 2-stroke
– Cylinder arrangement – Single cylinder
– Bore & Stroke – 89,0 x 79,0 mm
– Displacement – 491,4 cm³ (29,9 cu-in)
– Compression ratio – 6.8:1
– Max. power – 64,6 hp (47,5 kW) / 6000 rpm
– Max. torque – 72,2 Nm (7,3 kgm) / 6000 rpm
– Carburetor – 1x 38 mm

Drive train
– Clutch – Wet, multi-plate
– Transmission – 5-speed constant mesh
– Final drive – Chain
– Primary reduction – 2.520
– Final reduction – 3.500
I – 1.750
II – 1.388
III – 1.150
IV – 1.000
V – 0.870

Electrical
– Ignition – CDI

Project
https://www.vitalmx.com/forums/Bike-Builds,46/1992-CR500R-restoration,1337314?page=1

Rear shock bumper and bladder was from OEM, Racetech seal and dust cover. Nitrogen tank with 160psi.

Front forks – NOS Racetech .44kg springs. Honda OEM sliders, seals, dust wipers.

MSR poly bushings for the Scott risers .

UNI filter and a gas tank strap from 2004 CR250R.

http://www.oem-cycle.com/HONDACR500BIKEID.shtml

The wire harness were cleaned up and back in place and installed KTM pegs with minor fab work.

The radiators got some chemical cleaner which worked great at getting in the fins and small areas. Fins where straightened by two screw drivers. All the radiator hardware, clamps, hoses, etc… are in good shape except for the two hoses that attach to the cylinder head which were replaced.

Categories
MX Restoration

1995 Yamaha YZ 250 restoration/rebuild

This project was made with budged in mind so many parts are reused!

Project forum thread –
https://www.vitalmx.com/forums/Bike-Builds,46/1995-YZ-250-No-frills-no-bling-rebuild,1328872?page=1

Used parts:
  • 06 YZ450
  • .47 springs, 375cc of fluid
  • new swing arm, old was to damaged and cracked
  • front brake from Honda CRF – master cylinder, hose and caliper with a 270mm rotor.
  • rear brake master cylinder from YZ ’04
  • right side frame guard of ’98
  • came with log rod motor
  • later model rear brake master cylinder
  • Boyesen Rad Valve
  • Enzo subbies

Front wheel in good shape with spacers, rotor, axle and brand new front tire for cheap from eBay.

There was added some material to the steering stop so that the later-model clamps would make full contact.

Categories
MX Restoration

1995 Honda CR-250 restoration project part list

Projects parts:
  • ufo plastics;
  • PC porting and head mod;
  • PC works pipe and silencer;
  • Vforce3 setup;
  • Odi lock-ons;
  • CEET medium density seat foam;
  • Technosel seat cover;
  • ’94 shrouds;
  • forks and clamps are from an ’05 crf250 ;
  • gold excel wheels and dubya bulldog spokes and nipples ;
  • sudco carburetor;

Tail pipe was tweaked to clear the air box and bladder on the shock. Also cut the stock front mount off the pipe and rewelded it to work with the ’95 frame

Fork modifications – pressed the ’05 stem out and pressed the ’95 stem into the ’05 clamps.
New ’95 bearings and seals. 
Spanner nut from the ’95 but used the upper aluminum nut from the ’05. Measure your height of the stem in the ’95 before pressing it apart so you know you have the stem height correct.