'04 250EX build thread

[Baileygunns]

The begining teaser...

http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/010.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/011.jpg

I think the black frame with the red arms are going to look real nice! Still waiting on the swing arm and steering stem to get back from the powder coater (both black). I have new swing arm bearings, axle bearings and steering stem bearings ready to go in. This thing isn't going to be anything crazy... Basically a refurbish from the frame up. I'll add as I go but be warned, this isn't my top priority so it may take a while to build.

Hope you enjoy.

[700xxmaniac]

u should build ur engine too

[Baileygunns]

Originally posted by 700xxmaniac
u should build ur engine too
Build it like what? It's a 250EX, not a 450R... When she needs more power I'll get her a 400EX or a 450R.

[250ex_dan]

you should make it have some chrome and look like a TT quad if possible:)

[Baileygunns]

Front end is on... I put the harness on too but after the picture... Slowly but surely, lol

http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/IMG_0678.jpg

[HondaRacing83]

find a way to do a chain drive and it would be pretty sweet

[Baileygunns]

Originally posted by HondaRacing83
find a way to do a chain drive and it would be pretty sweet

LOL... Do you know anything about these bikes? No way possible to put a chain drive with the motor on these bikes... If I was to do a chain drive I would build the 250X I have sitting next to the garage...
http://i50.photobucket.com/albums/f348/Baileygunns/087.jpg

One project at a time my friend... One project at a time...

[Baileygunns]

Just got some braided front lines in the mail yesterday. They're Goodridge lines for $33 shipped off eBay, came with 3 separate lines with a junction connecter, new banjo bolts/washers and new clamps to hold the lines to the arms. Pretty nice little package.... The shop sticker on the package said $94.99... Guess I got a good deal.. Also got a skid plat for $40 bucks.

I have the rear end on (swinger, shock, diff, axle) and I just mounted the skid plate today... I'll get some pics later.

[Baileygunns]

Batteries for the camera are dead...

Realized the rear axle was bent, just ordered a new one today. Skid plate made it on with the wire harness. It's starting to look like a quad!... I'll grab some batteries today.

Still need to find some brake pads... I want to put some EBC pads (FA84R or FA84X) on this thing but having a heck of a time finding some cheap ones... Anyone running those cheapo $9.95 pads on ebay? I wouldn't run them in my 450 but might consider them for this bike.

[Baileygunns]

Working bare foot make me feel at one with the bike! lol...
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/001.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/002.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/007.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/008.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/009.jpg

[250ex_dan]

turning out nice:)
IS THAT red hub fading or dirty.?

[Baileygunns]

Dirty

[hondariderdylan]

lookin good:cool:

[Baileygunns]

I had some scrap aluminum in the garage so I whipped up a dash last night. It will bolt on top of the bar clamp. It has holes for the vent tube, neutral and reverse light and the key... Not sure if I'm going to slot it to add the choke to it or put the choke somewhere else.

http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/003-1.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/002-1.jpg

[Baileygunns]

Pics of the dash on the bike and brakeline kit (should go on tomorrow)...

http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/005.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/0032.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/0022.jpg

[250ex_dan]

Originally posted by Baileygunns
Pics of the dash on the bike and brakeline kit (should go on tomorrow)...

http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/005.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/0032.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/0022.jpg
looks good

[250ex_dan]

Originally posted by Baileygunns
Pics of the dash on the bike and brakeline kit (should go on tomorrow)...

http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/005.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/0032.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/0022.jpg
looks good

[Baileygunns]

Good news and bad news...

Good news is, the brand new nerf bars I won on eBay showed up this morning...

Bad news is, they are not for a 250EX but indeed for a 250X/300EX..

FML... :cuss:

[Baileygunns]

Got my money back for the nerfs... Back on the hunt for those.

Here she sits on all 4's. I put the calipers, lines and master on and bled them out. After bleeding hers it makes me realize how bad I need to change the fluid in mine, lol. Those Goodridge lines fit perfect and look great!

http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/001-1.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/0023.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/0052.jpg

[250ex_dan]

are those zuki rims.?
what nerfs are you getting.?

[Baileygunns]

Yeah, the rims came off a Z400 and I'm not sure what nerfs I'm going to get. I want to get a black on black set but it depends on what kind of deal I find... The ones I had were Pro Aluminum, the ones I was trying to get last night were AC Racing... I might order a set of Tusk today.

[250ex_dan]

do those zuki rims and tires make a difference in appearance.?
which do you think is better.?honda or zuki rims.?

[Baileygunns]

I thought they were all the same...

[Baileygunns]

A little update...

:mad: Me and the 250 aren't speaking right now.. lol.

I actually rode the stupid thing last night, to the end of the driveway and back... Still need to get a seat cover for it and a match set of rears for it. I fought with the gas tank last night, apparently the one I wanted to use leaks where the petcock bolts up and the other one I tossed on it is stripped out where the seat catch screws in... Errrr... But that's not why we aren't speaking. There is a chain rattle from inside the motor, it's either the cam chain or the oil pump chain, sooooo... The motor is coming back out. Now I'm figuring if I'm going to start working on the internals I might as well do a top end. I might even try my hand at porting and clean up the head...

Here she sits...

http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/0024.jpg
http://i50.photobucket.com/albums/f348/Baileygunns/250EX%20build/0033.jpg

[250ex_dan]

what type are those rear tires...?
holeshots/
have you rode it yet.?:)

[hondariderdylan]

Nice 450 BTW, and i love the teeth on the mower:p

Seat cover is a must, and if you can find a pair of nerfs from AC that are actually EX bars, buy them. i love mine.

[Baileygunns]

One tire is a holeshot and the other is a Carlisle badland, I still need to get a match set... I rode it to the end of the driveway and back, lol.

I think I might grab a set of Tusk black on black nerfs, I can find them on eBay for under $100 bucks and yes... The seat cover is on the list. As soon as I get a chance I'm going to swap out the oil pump chain and be back into getting this one finished up... I think I bruised a rib real bad the Monday before last on the 450... Kinda putting a cramp in my style! lol.

[250ex_dan]

which of those two rears tres are best.?
haha,,that was a far drive..:)LOL

[Baileygunns]

Well.... They're about equal.

I would run either one of them with out issue, you just can't run one of each. The Holeshot stays pretty flat across the top at low tire pressure. The Badland has a crown to it. If you were to ride a wheelie on it it would pull hard to the side the holeshot is on. TO even them out you have to WAY over inflate the holeshot and leave the badland with 3-4 pounds of pressure. Obviously not ideal for riding.

[250ex_dan]

do they look identical

[Baileygunns]

Damn near...

Carlisle Badland
http://static.summitracing.com/global/images/prod/large/crr-537032_w.jpg

ITP Holeshot
http://www.bikebandit.com/assets/product_images/07ITPHoleshotRearLG.gif

[250ex_dan]

do you know the prrice ranges for them.?
sorry for all the ?

[ryanh250ex]

Cool build. If you decide to send out the head for porting, shoot me an email first.

[Baileygunns]

I have a head on the bike and one sitting on the bench... Talk to me!

I'm in Titusville, 30 min south of Daytona or 45 min from Wyotech if that's where you are going to school.

[ryanh250ex]

Originally posted by Baileygunns
I have a head on the bike and one sitting on the bench... Talk to me!

I'm in Titusville, 30 min south of Daytona or 45 min from Wyotech if that's where you are going to school.

I'm familiar with Titusville....I have a real good friend of mine who lives in Mims, just off of Hwy 46.

Unfortunately, I have re-located back to NJ for good. I graduated from Embry Riddle in May, and moved back north in June.

Email me (address in the sig) and we'll talk.

[Baileygunns]

I emailed you... Did you get it or did it make it to your junk mail box?

[ryanh250ex]

Originally posted by Baileygunns
I emailed you... Did you get it or did it make it to your junk mail box?

Sorry! It was sittin' in my spam folder. I replied real early this morning.

[HondaRacing83]

bailey you should put newer body stile plastics on it :)

[Baileygunns]

Well... Me and the 250 started talking again, lol... I pulled the motor out of the bike today, tore the top end off, pulled the centrifugal clutch and the clutch, pulled the cam and cam chain out and finally got to the oil pump chain... Pulled it out and compare it to the other chain I had on hand. The one that was in the engine looked about a half link longer. You could see where it was rubbing on the inside of the case making all that noise. I put the new chain in and put everything back together. Then as I'm looking at the piston I notice one it's brand new with no carbon on it at all, a good thing. Then I notice the "IN" engraving was on the exhaust side of the engine, a bad thing, lol.... Apparently the person that was in there before me was not so smart. I pulled the circlip and spun the piston so the "IN" was in the intake side like it should be, back to a good thing, lol.

Now I just need to order a top end gasket kit and put the top back on. I'm going to port the head on this thing too. I'll take some pictures of the ports as they are now this week before I get into it. Wish me luck on that... I guess if I mess it up I have another stock head on the bench I can fall back on, lol.

[Baileygunns]

I kind of gave up on this thread/forgot about it, lol... Didn't seem like much intrest.

Here's the bike all done (poor cell phone pics). She took it out and rode it this afternoon. She did very well considering she hasn't riden a quad since she was 10, lol. Most inportant part is, she LOVED it!!

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1337.snc4/162903_482730765668_661520668_6043507_8103633_n.jp g
http://l16.sphotos.l3.fbcdn.net/hphotos-l3-snc6/hs005.snc6/165547_482730310668_661520668_6043504_222130_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs749.ash1/164043_482729930668_661520668_6043500_6034232_n.jp g

[250ex_dan]

congrats on the finish
looks good

[yamahaXC13]

great job on the build bailey, looks great very clean, anyways I was wondering if anyone on here could help me with a build of mine well actually my buddys 250 ex, he told me that the engine smokes alot and that he would like it rebuilt, I never seen it run before and the engine is already out of the frame so I dont know how bad it is, I'm going to be tearing this engine apart either this weekend or the next and I was wondering if anyone has any tips,advice,or simple step by step on how to rebuild it, I've rebuilt a number of 2-stroke engines with success but never rebuilt a 4-stroke before so any help would be great, thanks

[Baileygunns]

Sorry I didn't see this sooner... Rebuilding these 250EX motors is easy... It's either smoking from worn rings or maybe a valve seal... Both are pretty easy fixes... Hear is a link to a service manual... Everything you need Bro. This is a link to my own account so I know it's virus free...

http://www.4shared.com/document/U5Tbpb2o/Honda_Trx250ex_Repair_Manual.html