My Dream Duner Build

[Motofool250r]

Here is the Thread im going to start on my Duner Build that started with a hunt for a nice new frame for my current 250r and turned into me building a bad *** bike n giving my current one to my father to ride with me.

[Motofool250r]

Motor 6mm stroked puma 443cc

[Motofool250r]

So far,

JP race frame
PUMA motor By Hybrid Engineering in Camas WA
6" Over round bar swinger
+2 Front suspension with Custom spindles n Billet hubs
Works triple rate front shocks w/ Res
LSR steering stem,
LSR Rear Axle
LSR carrier
LSR Hubs
LSR Anti Fade
LSR Seat Latch

Janseen OS radiator
IMS 4.3 Gastank
FullBore Front and Rear Plastics with CF Hood


Motor 443cc
Puma Cylinder
6mm Stroked crank
Yukon Gear set
Hinsen clutch
V force reeds
Lectron 44mm
CR250 ignition
Matt Shearer custom inframe pipe

[Motofool250r]

here we are test fitting before we tear down to powder coat everything the colors we want

[Motofool250r]

Spindels n brakes mounted

[8686]

Wicked sweet build.

[Motofool250r]

so far im going with a candy bright green n grey white black combo most of my parts are polihed or chromed though

here is a sneak peek of the color im thinkng of

frame, springs calipers, spindels, some of the motor mounts

[Motofool250r]

this one

[Honda 250r 001]

you got some yukon gears for the puma! WOW!! what torque and hp r u gonna be gettin with that? got a lock up clutch? lol

[Motofool250r]

the last one made jsut like this one tuned n dynod 96hp at the wheels mine isn't gonna be that tuned or having a OOF pipe so conservative number 80RWHP

[Motofool250r]

mounted sort of waiting on bolts from service honda

[Motofool250r]

rear suspension mounted up n motor in frame

[Motofool250r]

front shot

[Motofool250r]

left side

[Motofool250r]

fatty shearer pipe that needs to be chromed =)

[woodsracer144]

Originally posted by Motofool250r
Here is the Thread im going to start on my Duner Build that started with a hunt for a nice new frame for my current 250r and turned into me building a bad *** bike n giving my current one to my father to ride with me.

you didnt happen to get that chassis off ebay did you?

[woodsracer144]

Originally posted by Motofool250r
mounted sort of waiting on bolts from service honda

what size motor is that now with the puma on there... i thought those were a 340 fan? what years are liquid?

[Motofool250r]

it has a 6mm stroker crank and with the current bore its a 443cc

its an aftermarket 250r cylinder made by CP industries out of oklahoma

my engine builder is out of Camas WA and hes the man on 250r's

[Motofool250r]

they make a Puma, a Sabertooth and another cylinder i believe

[Motofool250r]

yes i did was 511$ pretty good deal ive got some things i have to fabricate for it but im satisfied with it


Originally posted by woodsracer144
you didnt happen to get that chassis off ebay did you?

[woodsracer144]

yeah i though so... i almost bid on it... :devil: :scary:

[woodsracer144]

Originally posted by Motofool250r
Spindels n brakes mounted

who made those?

[Motofool250r]

guy in vegas i was told for desert racing dont know much about them

[Saleenster]

That is coming along very nicely. Pete has some good porting on that cylinder, it should run pretty good.

[250r grave yard]

thats a sweet motor Motofool250r cant wait to get mine next week just got to slap it on and tune 431 on pump gas


bump for a puma :macho :muscle:

[Motofool250r]

yea right now just doing some motor mount mods to the frame and stiffening up the rear of the motor n fixing the lower motor mount tabs n bar. after thats done it will get dissassembled n shipped to oregon to be powdered n then dropped off at cascade to have them modify the silencer and the seat cover.

we had to make custom radiator mounts to fit this janseen radiator in properly.

we did figure out a stock 250r cable does not fit the lectron carb at all have to use an atv 85 cable or one from packard racing.

[Motofool250r]

heres some updates

with the larger puma cylinder and longer reed cage setup the airbox nolonger fits without modifications it pushed everything back 1" so trying to find nice solution before just sticking a filter on the carb.

[Motofool250r]

heres the brake setup,

[Motofool250r]

air box problem

[Motofool250r]

another

[250r grave yard]

Motofool250r let me know how the air box goes on power wise im a big fan of the air box also protects your air flter along with the motor but it does reduce some air flow and the bike s coming along nicely keep it up

it seems lke im going to pick my new r this week some time shippng going to take to long and my puma motor hopefully comes in this week but m ride the 370 till the puma gets in

[Motofool250r]

my airbox wont be stock but i dont want my filter in the open air either alot of motors gain power by putting the air box back in less air movement from the tires back their

[250r grave yard]

whats not gong to be stock bout your air box

[Motofool250r]

once we get the mounting figured out ill get an auminum one that has less restrictions and probably give it more airflow too

[250r grave yard]

are you planng on powder coating the frame if so reweld the brackets

[Motofool250r]

dont have the eq to reweld the chromoly to the standard id like, so getting brackets moved n such is more costly then a custom airbox

n yes the frame will get a full blast n powder job as will the whole bike soon as everything fits n works to a ridable standard.

gotta make a custom bracket for my new hydralic custom clutch setup also.

[250r grave yard]

are you running the lockout clutch

[Motofool250r]

not yet, ill get one next summer probably just want to break this thing in and ride it this round ill have a new swingarm arched n more goodies after this september ride

[buford]

where is this bike going to be ridden? If dunes only, keep the stock air boot, make an adapter so you can mount the filter on the stock boot and loose the air box. Use a stock style K&N filter and an outerwear and you will be fine. That's how I have been running mine for years and never had a problem with the filter being sandy even in the wetter months. I would be more fearful of starving that big puma with the air box on even without a lid. The aluminum air boxes you buy are usually hardly a air box so why bother. If it's a dirt only machine that's a totally different story.

Don't put the filter right on the carb, not near enough air with the tiny filters that go on them and you loose the venturi effect the tuned stock air snorkel provides.

[Motofool250r]

bike will live in the dunes only.

i may do just that make a bracket to adapt the filter boot to the stock Filer since i just bought a brand new one n 2 outerwears for it.

just real leary of leaving it open back there by the tires seen too many dead motors from the carb filters getting loose

[norcalduner]

Ya might need something similar to this. This is a LSR no link airbox that came off my JP frame.

[Motofool250r]

norcal u hanging on to that box?

=-)

[buford]

I went down to an irrigation pipe supply place locally and bought a 4" piece of aluminum pipe and then make a bracket around it so I could mount this to the frame. The stock air boot mounts to one side and the filter to the other with the hose clamps that come with the K&N filters. I can tell you the filter won't come loose. I put the outerwear on the filter. Like I told you, I have been running this set up the last 5-7 yrs without any motor issues at all. There isn't a speck of sand in the air boot and honestly the filter rarely gets much sand on it with the outerwear.

I have this same exact setup I described on my Puma. I wouldn't even bother with the lonestar air box, you would be wasting your money.

[norcalduner]

William ... it is yours if ya want it. I was kinda keeping it just in case I restore my JP back to its former glory hahaha. Its got a ding though on the bottom where it hit the rear caliper. Here's another pic.

[Motofool250r]

almost there

[Motofool250r]

dont even say it about the seat cover its not staying like that =)

[woodsracer144]

holy mon-do seat!

[Motofool250r]

i prefer desert seats due to riding position n not having cramped legs, gonna have cascade make me a custom cover for it though

[jrlj]

that motor has a lock out unless you or Pete took it out

[Motofool250r]

i havent cracked the cover yet i will now that u say that i was gonna order a gigot one if it didn't

[jrlj]

it does, gigot, hinson basket, works great.

[Motofool250r]

awesome cant wait, only hurdle ive found so far s a silencer to pass sound, cory has a used cascade that pete cut down forsale but it has no mounts on it for the frame or a stinger pipe. so looks like my best option is to drop it off at cascaden have them make it fit right but thats gonna be spendy 275$ plus 120 for stinger.

n then a new seat cover n get dropped off for a set of Lew junior pegs n a fresh coat of candy powder

[Motofool250r]

Some updates here

Puma as of 2011 (picture)

as this pic was taken we were scratching our heads trying to figure out how to get er home as it broke all the mounts off the aftermarket frame.

only swingarm holding it together.

Now there is a new LSR frame with some custom mods done to it.

We removed all stock motor mounts and beefed them up and made them much stronger.

New Swingarm and Subframe are in the works.
Have a PEP rear shock setup for +6 swinger to use also.

Front suspension is changing, removed +3+1
Swapped for Rolldesign +2
400ex spindles, and calipers LSR hubs and new HLS front shocks.

Updated the paddles to 12 paddles Ext with drag cut wheels
Just got some new triple buffed mohawks and drag cut fronts.

also have a couple drag axles to play with on the rear.

everything is waiting for polish work, powder or chrome.

finished product update in a couple weeks here.

[crlt250r]

Snapping off the mounts? That's some wicked sick power there! Had the same issues with the old CR motor in my LTR frame, that was because the frame was rusted apart though LOL

[Motofool250r]

Originally posted by crlt250r
Snapping off the mounts? That's some wicked sick power there! Had the same issues with the old CR motor in my LTR frame, that was because the frame was rusted apart though LOL

first ride i broke 2 sets of front motor mounts(triangle shape) one old stock set and new chromed set, then i went and bought 3 sets for spares until i found pumashines set.

the ones he makes are stainless(polished) and they haven't broken and are reasonable price at 55$

[crlt250r]

I may have to keep that in mind. I just got rid of the Honda motor, and put in an RM motor. Running the factory mounts now, looking to see how they hold up for its first outing today.

[Higgy87TRX425]

Hey Will,
I bought an Airbox eliminator kit, cut the tabs off where they hook up to the frame just the same as a standard airbox does. Well then I had the tabs lengthened that 1" inch that I needed just like you need. I have had that same problem with my Puma in my Roll frame. I'll see if I can find some pics of the lengthened tabs so I can so ya. After they're lengthened the 1" inch then I used an 86 boot and a K&N filter with an Outterwear!
Problem solved. It looks good too!! There's even a place to put your rear master cylinder!!
http://i979.photobucket.com/albums/ae274/543215196/Airbox%20eliminator%20kit/Airboxeliminatorkit004.jpg
Here's what they look like before and after!
Thanks Higgy!

[Motofool250r]

Higgy, i saw that before

i have 3 of those eliminators, and my new subframe will have both airbox grommet locations normal and 1inch further back so that if i take the puma out of this frame it will work with stock.

[Motofool250r]

Got a few updates Some pics from the polisher, and new toys showed up

[Motofool250r]

Two shocks to choose from here both setup for +6 swingarms

[Motofool250r]

And a Brand New LSR Drag Axle, Got one for both bikes the 443cc and the new 344cc build

[Higgy87TRX425]

Yes becasue you're just changing the length of the tabs on the eliminator kit. The kit will only work with a bigger motor like the Puma from now on, but who cares I only plan on using it on my Puma! Here's another Pic of it on the bike. You're not changing anything on your subframe the only thing permantely changed is the airbox eliminator!
http://i979.photobucket.com/albums/ae274/543215196/LoPuma%20Project%2020/LoPumaProject20066.jpg
See!
Thanks Higgy!

[Motofool250r]

Higgy,

no im having a new subframe built with dual mount tabs. so i can run it in either location.

but your idea is great if you only run the puma in that frame and dont want to modify the frame.

[J250r]

Holy quintuple post batman! :D

[sameltoe]

Originally posted by J250r
Holy quintuple post batman! :D I thought maybe Higgy was stutter texting??:p

Man you guys and these builds are just amazing! Makes me wana hide all my arens build threads lol

[etccb]

Makes me feel bad about my stock frame stock aarm stock axel build. If we just don't park ours right next to these guys we'll be good sameltoe.

Another day closer fool. :)

[Motofool250r]

Well this is multiple phases and an addiction im on the road away from home with nothing to do but look on the net and dream up **** to do to my bike.

i started this in 2009 and its now 2012.

i was gonna stop with the red JP frame and just enjoy it then i broke it again.

figured i cant stop here i was so close.

I have a big load of parts headed to the chromer and powder coater soon.



Etccb and sameltoe we have 2 stock frame bikes in the shop also.

pics coming of wolvmans build soon.
its gonna be pretty sweet too.

[Higgy87TRX425]

Motofool250r
So last night I was trying to get that post to go threw to the thread and it just wouldn't do it. I tried other websites and everything else worked fine, for some reason it was this particular site that was overloaded at 3am my time weird. So I just kept deleting today and I guess I went to far because that one's gone now, oh well it was a pain in the *** anyway! Sorry about that guys!
So ur having a whole new subframe built just becasue of the mounting locations. That doesn't sound right, I know you've got some modified hidden version of a subframe in the works! Those Axles are a great idea too. A good way to keep that HP to the ground without breakiing anything! I just dropped alot of dough at LED so I'm awaiting my Spyhnx 350 right now! Should be fun. I can't wait to ride with ya!
Thanks Higgy

[Motofool250r]

the subframe was being made anyway, so the airbox tabs were easy.

on the other frame we drilled a holt used a long 1/8" screw (2" long) and some nuts and loctite to make mounts further back

like this

Grommet goes on here>> (===|[Frame]|=

[Higgy87TRX425]

Originally posted by Motofool250r
Higgy,

no im having a new subframe built with dual mount tabs. so i can run it in either location.

but your idea is great if you only run the puma in that frame and dont want to modify the frame.

Motofool250r,
You can just use one of the stock eliminator kits that hasn't been modified if you wanna run a smaller motor that doesn't need the extra inch! The whole idea behind this was to keep the frame the same so that I didn't have to permantely change anything on it. That way if I wanna go back to a stock style or size motor I can. The tabs on the subframe stay in the same location!
Looks like your build is gonna be a nice one!! You're getting everything together. its like X-mas, only better, because you're getting everything that you want, lol!!
Thanks Higgy!

[Motofool250r]

Originally posted by Higgy87TRX425
Motofool250r,
You can just use one of the stock eliminator kits that hasn't been modified if you wanna run a smaller motor that doesn't need the extra inch! The whole idea behind this was to keep the frame the same so that I didn't have to permantely change anything on it. That way if I wanna go back to a stock style or size motor I can. The tabs on the subframe stay in the same location!
Looks like your build is gonna be a nice one!! You're getting everything together. its like X-mas, only better, because you're getting everything that you want, lol!!
Thanks Higgy!

Just a different way man, i wouldn't modify that roll subframe either.

[Higgy87TRX425]

Motofool250r,
Yeah I thought of doing something like that at first too, but I just didn't want to drill threw the frame. Plus I wasn't sure how good looking it would turn out? So thats why I went the way I did! I'm sure yours will turn out real nice and be pretty versatile which is always a good thing. These builds fight us enough as it is! I guess thats what makes them fun! Keep buying all these nice parts and ur gonna have a hellva sick "R", lol! Alrightly gotta run for now!
Thanks Higgy

[Motofool250r]

So yesterday we picked up the frame from the fabricator after he chopped up a perfect LSR frame. Some would cry other will love it like me!

https://lh4.googleusercontent.com/-XHxzE0EA9To/UA66K4lTpYI/AAAAAAAAFLo/cgsy75A7rCQ/s665/back+side.jpg

https://lh6.googleusercontent.com/-A1CpkrqjHcM/UA66H9_k6JI/AAAAAAAAFLU/hn9k1CpPSck/s640/photo+%2859%29.JPG

https://lh4.googleusercontent.com/-IKRA8JlwCVU/UA66H7XQz2I/AAAAAAAAFLY/6HkG0_q6Q64/s598/photo+%2860%29.JPG

https://lh5.googleusercontent.com/-yAvGiSmc5oQ/UA66KpN2jNI/AAAAAAAAFLk/rQtlRSgvoU0/s598/photo+%2861%29.JPG

https://lh3.googleusercontent.com/-dvwVgR_MHjA/UA66LNYUGpI/AAAAAAAAFLs/PGKplChrWko/s640/photo+%2870%29.JPG

https://lh5.googleusercontent.com/-gEO_Kcho2Bg/UA66SVSCOyI/AAAAAAAAFME/Lg5Y4GsrSYc/s597/photo+%2871%29.JPG

https://lh5.googleusercontent.com/-SpWJaTe8j7E/UA66SKk0n2I/AAAAAAAAFMI/wQajQX2E-SU/s598/photo+%2872%29.JPG
https://lh6.googleusercontent.com/-CmCCTyKFbSA/UA66PPlJypI/AAAAAAAAFL8/agK94hUMBb8/s598/photo+%2874%29.JPG

https://lh4.googleusercontent.com/-gPHgSjIPNFw/UA66WXh1Z0I/AAAAAAAAFMU/y-l8f6rS2Xo/s597/photo+%2875%29.JPG

https://lh6.googleusercontent.com/-hFLX6QJ3lfA/UA66ZEGdYMI/AAAAAAAAFMc/JOB8Mz75N8A/s598/photo+%2876%29.JPG

https://lh5.googleusercontent.com/-auGbpoUEwoY/UA66aDQcB8I/AAAAAAAAFMk/wAOMM5GgJMg/s598/photo+%2878%29.JPG

https://lh4.googleusercontent.com/-iClYdi8i_M0/UA66fkHZlRI/AAAAAAAAFMs/aL5kIgFVcfI/s598/shadow+2.jpg

https://lh6.googleusercontent.com/-R5C0Suhl54s/UA66gJG1BkI/AAAAAAAAFMw/sBbcXr3Jm84/s598/shadow+3.jpg

https://lh3.googleusercontent.com/-S7jNxQaFGyQ/UA66iCYbGoI/AAAAAAAAFM8/w8lMaysEZuI/s597/shadow.jpg

https://lh3.googleusercontent.com/-6Jip3Ock6UE/UA66kWSWRqI/AAAAAAAAFNE/7B39iwgD4ZE/s597/side+view.jpg

To summerize he Made all new motor mounts because of issues i had before of the frame not being able to withstand the torque and abuse of the Puma

Wide foot pegs made

then he made a new rear subframe and arched it to the back to integrate the grab bar into it and setup two sets of mounts for the airbox eliminator plate one for small red motor (proX Sphynx, and one further back for the the Puma cylinders in this chassis)

he also fixed my pipe that someone had fubared up with the slip joint on backwards and leaky

Now it is off to be Acid dipped and polished then to be chromed and Powder coated.

[sand_blaster]

Looks amazing!! Who did the frame work?

[Motofool250r]

Sand Fab in Portland Price was execellant too.

[Motofool250r]

Seat Sneak peak

[Motofool250r]

Motors home

https://lh4.googleusercontent.com/-BeM56aF7H1E/UA9mOgwAztI/AAAAAAAAFNo/pqLN1U4FeSI/s598/photo+%2869%29.JPG

https://lh5.googleusercontent.com/-1CEkrj3n96c/UA9mO22XI6I/AAAAAAAAFNk/r9T2wqs-66E/s597/photo+%2870%29.JPG

https://lh3.googleusercontent.com/-b2_i2JTsjkw/UA9mPoqAGJI/AAAAAAAAFNs/TbKBSZv_Q-c/s797/photo+%2868%29.JPG

443cc Puma, +6mil stroke
Slingshot Lockup
Hinson basket
Yukon Gears
cr250 ignition
Vforce Reeds
40.5mm PWK taper bored
Mated up to a Shearer inframe pipe.

Cases Polished by Traxman
Cylinder Paint by Pumashine

[Motofool250r]

Tim over at Stellar Performance sent me a sneak Peak on the swinger Fab

[Motofool250r]

and another

[crlt250r]

Holy crap... That is beautiful! Gotta have em build an extra one to set on your mantle!! Swinger is a work of art, great job!!

[Motofool250r]

thanks for the Kind Words

[sand_blaster]

Tim does great work just got my lower a-arms back from him! Looks like hes making you a sweet swing arm

[Motofool250r]

post up the arms he made you.

[Motofool250r]

update from Traxman (Damon)

He spent a lot of hours making these things so beautiful



https://lh4.googleusercontent.com/-KDbwx6DKvMs/UBu-pkRUT8I/AAAAAAAAFPQ/DWV3ZFx1pJ0/s886/asdf.png

https://lh4.googleusercontent.com/-ehJqwZ8v2uI/UBu-qEqZ2OI/AAAAAAAAFPU/AQyK-OqTVbw/s887/asdf2.png

[tbone250r]

this build is shapin up to be pretty sick. Look forward to seeing it finished

[Motofool250r]

time frame is short have to be done before end of august as im flying back from europe to go ride it! September 1st

[etccb]

Very sparkly!!

[Motofool250r]

Tim sent me an update on the swingarm it was finished and went to chrome yesterday

https://lh6.googleusercontent.com/-2exp0zvKhLU/UBnLP7ex34I/AAAAAAAAFOQ/cRl_VN7Magk/s1014/2012-08-01+11.58.21.jpg

https://lh6.googleusercontent.com/-ZWBaQAJxKiQ/UBnLP7Lx6wI/AAAAAAAAFOU/0Cr-l-1SFqc/s640/2012-08-01+11.58.46.jpg

https://lh4.googleusercontent.com/-JA6pNAiR2y8/UCEfkXWmEgI/AAAAAAAAFP0/qHWpP2D-NV8/s825/2012-08-06+14.33.11.jpg

https://lh4.googleusercontent.com/-7TwdVv_Y8HA/UCEfjw9DQMI/AAAAAAAAFPw/pkq25J2xTZc/s615/2012-08-06+14.33.29.jpg

https://lh3.googleusercontent.com/-3gwbsseh3dk/UCEfkjKNjkI/AAAAAAAAFP4/uwsr9Lfcb1g/s1009/2012-08-06+14.33.39.jpg