2010 Laeger TRX250R Project "Elsinore"

[tbone250r]

Got anymore pictures or updates on this Troy?

[troybilt]

Yes I do they are on the home computer. I'll take some tonight as well. Just about done. Should be completely done by March or so.

[Flyin_250r]

Troy where's the updates?????? We all have been patiently waiting!!!! Lol

[troybilt]

I'm dangerously close to being finished with this build after 3 years!! Installed the chain/sprocket today and also set the caster/camber/toe on the front suspension. Still waiting on the carb from BDT then I'll be ready for some heat cycles. Pipe and silencer are finished, and the tank looks gorgeous!!!

Soon, within the week it will be ready!

Clear ceramic coated pipe:
http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/0201131726_zps6927a8d5.jpg

Tank mounted and finished:
http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/0201132033a_zps9a4e8b63.jpg

http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/P3120077_zpsbcc64781.jpg

[troybilt]

http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/P3120076_zpsfc8899f3.jpg

[troybilt]

BTW, I've revised my theme since 2010 This is the theme I'm going for...

http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/2-13crf_zps8ce67104.jpg

[atv fan 28]

I cant wait to see how this baby does. Don't see too many Sabers in a MX chassis.. :p Gonna be a beast!!!

[beobe99]

Your builds literally hurt my feelings they're so sick..

Keep it up!!

[troybilt]

Few more pics. I'll post video when I get it running....

http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/P3160009_zps2db97e02.jpg

http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/P3160007_zps44015987.jpg

http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/P3160004_zps3013b451.jpg

http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/P3160003_zps58600783.jpg

http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/P3160002_zpse2a3c311.jpg

http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/P3160001_zpsecf59a88.jpg

[etccb]

Looks killer! I love the theme.

[redrider419]

Damn.

[Grande Huevos]

You defiantly have a very sick toy!!! At First I wasn't a fan of your pipe but its been growing on me as this thread has gone on, and now I think it may be my favorite part of your bike! You did a nice job with everything it and paying attention to detail! Please give a ride report when you get the chance.... Maybe post a video of you running her???

[89trx250r]

Looks great! How many times have you just walked over and sat on her since shes off the stand? I would have spent at least 20-30 mins bouncing around on the shocks and just messing around :)

[pepshocks]

Great build man!!

[Flyin_250r]

Try sick job! Absolutely love it.

Ive seen a few threads where you have designed graphics for people. Is it a ton of work for you? Im thinking about copying somewhat the design I already have on my hybrid, but change up the colours, wording etc.

You definitely need to post up a video of this beast going for a rip.

How did you come up with the design of the pipe? Did you somewhat copy the dimensions from another pipe, or come up with it on your own? Just curious what it takes to match a pipe to the engine etc. Im sure a few of us would love to hear it :)

[troybilt]

Originally posted by Flyin_250r
Try sick job! Absolutely love it.

Ive seen a few threads where you have designed graphics for people. Is it a ton of work for you? Im thinking about copying somewhat the design I already have on my hybrid, but change up the colours, wording etc.

You definitely need to post up a video of this beast going for a rip.

How did you come up with the design of the pipe? Did you somewhat copy the dimensions from another pipe, or come up with it on your own? Just curious what it takes to match a pipe to the engine etc. Im sure a few of us would love to hear it :)

The graphics aren't too bad. Kind of depends, sometimes I can whip them out in a couple hours, sometimes it takes several weeks to get it right. Either way I charge the same.. lol!

I will forsure post a video and ride report. Plan to take it out this weekend if the carb shows up. Its full of fluids and ready to go.

I posted a full build thread on the pipe on the other site. I wrote a program and designed the pipe myself. I did use a CR500 pipe as a guide. This was the first and only pipe I've ever done, so I've got some work to do to fine tune the design.

[troybilt]

Originally posted by Grande Huevos
You defiantly have a very sick toy!!! At First I wasn't a fan of your pipe but its been growing on me as this thread has gone on, and now I think it may be my favorite part of your bike! You did a nice job with everything it and paying attention to detail! Please give a ride report when you get the chance.... Maybe post a video of you running her???

Thanks! I will forsure post up video or several of it running. Pipe is a work in progress, this is the first one I've done...

[tbone250r]

I love the theme you have goin Troy. I might have you do something with mine like that.

[312R1]

Awesome job Troy...Pipe is just down right sexy!

[FW_cArBoN]

Love it Troy! By far my favorite R! :)

[J250r]

Such an awesome build. Not ashamed to admit that I've read every page of this thread more than once.

[troybilt]

Thanks I appreciate the compliments. I look forward to updating this thread with some videos!! Picture is worth a thousand, but video is worth a million.... LOL!

[dlunn]

Nearly 79000 views has to set a record for most viewed atv ever!!! Great looking build.

[Burns310r]

Hey Troy,
What Chain and Rear sprocket did you end up using? Id like to have a blue sprocket like that.

[troybilt]

Originally posted by Burns310r
Hey Troy,
What Chain and Rear sprocket did you end up using? Id like to have a blue sprocket like that.

PBI Sprockets, recommendation from the other site...

http://shop.pbisprockets.com/

Seem like a good steel sprocket, no too costly.

[troybilt]

Originally posted by dlunn
Nearly 79000 views has to set a record for most viewed atv ever!!! Great looking build.

Thanks! I don't know if its the most viewed ever, taking 3 years to finish certainly has something to do with that.. LOL!

[troybilt]

Forgot to mention, went with a 15:38 front sprocket to rear ratio...

[312R1]

Originally posted by troybilt
Forgot to mention, went with a 15:38 front sprocket to rear ratio...


That's the gearing I have always ran. Love it.

[bansheebc]

That did turn out awesome. You going to chrome the pipe? That'd be a nice touch. blinging

[dustinshuler]

Troy, It really has turned out awesome! Ive really enjoyed watching this build! It has inspired me on many occasions!

[troybilt]

Originally posted by dustinshuler
Troy, It really has turned out awesome! Ive really enjoyed watching this build! It has inspired me on many occasions!

Thanks Dustin, you've inspired me many times as well..... and several times over I might add!!! LOL!

[JohnBeton]

the color scheme is off the hook !.
Clean and simple, I like that.

[pepshocks]

What motor r u running in this?

[troybilt]

Originally posted by pepshocks
What motor r u running in this?

Powertrain consists of:

BDT 496cc Saber Top end, raised porting and de-tuned to mid-upper 60's hp, fresh nikasil, with enough torque to rotate the earth... Slingshot clutch, Hinson basket, all new OEM gears, all new bearings, balanced crank, 40.5 A/S carb, Artic Cat 700 VForce 3 reed cage, Brand new CR ignition, and a Custom pipe built by me.

[troybilt]

i.e. this Behemoth:

http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/P3160001_zpsecf59a88.jpg

[tbone250r]

We want vids! We want vids! We want vids!

[troybilt]

After a carb shipping debacle and stator issues... Elsinore lives! Sounds extremely healthy and crisp. I fired it up for the first time tonight... I'll post video soon. (kids are sleeping tonight... LOL!)

[Skyman]

Originally posted by troybilt
Forgot to mention, went with a 15:38 front sprocket to rear ratio...

Troy, first of all off the hook project! Second with the 15 tooth front sprocket, what case saver did you use? My engine was also Build by Carlos at BDT but the case saver he installed did not allow for a 15t. Suggestions?

[312R1]

Originally posted by Skyman
Troy, first of all off the hook project! Second with the 15 tooth front sprocket, what case saver did you use? My engine was also Build by Carlos at BDT but the case saver he installed did not allow for a 15t. Suggestions?

I ran a Duncan one and it worked fine with the 15 front.

[Skyman]

I will try the Duncan. Thanks

[Allison55ex'er]

I remember when you first started this build man it's changed shape quite a bit and I Really like the way it turned out. Time to get it dirty!

[troybilt]

Elsinore Ride Report, after 3 years in the making:

I survived the first trip with Elly. She is befitting of the name in more ways one, nothing but trouble! I'll get to that in a minute LOL!

Started out I recieved the carb from Carlos Saturday before the trip. (We left on the following Thursday morning, Apr 11). Carlos was kind enough to air freight the carb to me, after the original carb he built for me was lost in the mail on its way back from Hawaii!! LOL!.. Anyway I finally recieved the carb Sat, and then tried to get my bike to fire, but now no spark. All day Sat/Sun I was chasing electrical gremlins. Finally came to the conclusion that the stator was bad and wasn't producing a spark (CR Ignition..). So I again call Carlos up Sunday afternoon and he air freights me an entire CR ignition brand new to try, first thing Monday morning. Well it didn't take long to get the bike fired up this was Tuesday night, 2 days before the trip. So I did several heat cycles that night and again on Wednesday so my bike wasn't totally fresh on Thursday at the dunes. I never got above 1/4 throttle so I couldn't tell how far the jetting was off. Started out with a 40.5 PWK, 205 main, 58 Pilot, DGH needle middle clip.

Once we got to the dunes Thursday afternoon, I was able to run the bike a few times around the camp ground and could tell she was a dog. Seemed wayy to fat on the jetting. So I called Stewarts up in town of Waynoka to get my bike on the dyno so I could figure out the jetting. I was paranoid about being too lean so I wanted it to be right. Stewart's agreed to run the bike Friday morning.. (nice birthday present to myself!! LOL) The rest of Thursday afternoon/evening I didn't take the bike out at all. I just ran several more heat cycles and setup our campsite.

Friday comes around and we go into town first thing in the morning to see if we can get Elly running right.

http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/dyno2_zpsaecde23e.jpg (http://s74.photobucket.com/user/robltc/media/Elsinore%20Part%202/dyno2_zpsaecde23e.jpg.html)


http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/dyno1_zpse7cfc457.jpg (http://s74.photobucket.com/user/robltc/media/Elsinore%20Part%202/dyno1_zpse7cfc457.jpg.html)




Dan has the videos of the dyno runs, I'll see if he'll post these up for you to view.

On the dyno, the first 3 pulls we learned what I first thought, she was a dog!! Wayyyyyyyyyyyyyyy to fat, pulled around 44hp with the stochiometric readings in the 17's-18's... really high. He told me to go to a 170 main and leave the rest. So I swapped that out, and then she wouldn't start... at all... and just peeing fuel out the bowl. Apparantly there was some dirt caught in the float needle valve holding it open. So we took the carb out and disassembled it to clean the dirt out. Swapped the 170 main and we were ready for a few more pulls. This whole time there was 10-15 people standing around watching me which is a little nerve racking by itself... I like to tune in private... LOL!

Next runs were much better, but still really fat and doggish in my opinion and showed in the dyno charts. That one change to the main pulled the hp to 54-55-ish with torque in the 38 range. Very nice torque, but the low end responsiveness was still really sluggish. The Stochiometric readings were still stupid high on the low end, however, Randy Stewart told me to run it like this since she's a new motor. So he printed me some sheets from the dyno and we load back up to head back to the dunes. I wasn't really statisfied with the dyno runs, felt like I had more questions than answers on the jetting at this point.

NOte: Some were asking me about the clear ceramic coating... don't mess with it. I did mine and 150 dollars later it was gone. It didn't last long on the pipe. She got too hot on the dyno, my temp gage was over 250 after the last pull, and ceramic coating rubbed right off... I was getting a little nervous about that as well. Also my exhaust was a touch too loud in my opinion. I think I can do better, there with a new silencer. Next silencer will be a 3.5-4" can. It does sounds ridculously mean though now!!

SO now we are back at the dunes Friday its after lunch, bike is running ok, still really fat on the low end, but I was able to take here out for the maiden voyage. She ran real hard on the top end, you could tell it was a top end ported motor. You can take the drag motor out of the drag bike but you can't take the drag porting out of the drag motor! However, the way the pipe is designed it really smooths out the power. There was no hard hit at all. Smooth pull that seemed to never stop, just like a fourstroke and what I wanted. I just need to wake up the low end so it pulls off the start.

I decide to take it back into camp and switch out the pilot jet for one a little smaller, I go down to a 50 instead of a 58. Then my dad and I go back out by ourselves to see what that did for me. WOW, holy crap!! that made a world of difference. It was pulling real hard from off throttle to all the way up to 10,000 rpm, crazy. ..................Unfortunately, unbeknownst to me, the spark plug boot was loose on the coil and after I hauled *** from the gate my bike died and wouldn't start I was like F-k, now what... I thought I just burned a hole in the piston... Luckily when we towed it back to camp my dad noticed the plug boot was off of the coil. Phew!! So I then decided to check the pilot jet took the bowl off and noticed it was sitting in the bottom of the bowl!!! I have no idea if it was running so good with the pilot loose and in the bottom of the bowl. So then I decided to go one more size lower on the pilot to 48, nada, that didn't work had now power on the bottom... I thought maybe it ran so well cause the pilot was letting more fuel past so I go up to a 68 pilot and even took the pilot jet out, and tried more of the same... the bike wouldn't pull inself in first gear. I couldn't get it move even feathering the clutch. Almost like it was an 80cc motor. Wasn't making sense. I went up and down on the pilot to wake that back up, once it did get going on the top end was fine. I tried everything. NEver could get it to run like it did after the dyno runs. Seems like something else is wrong. I must have taken that carb apart 40-45 times Saturday, even went back to the exact same jetting as I started. I'm thinking when we pulled it in after the spark plug boot or something I could have broke a reed on the reed cage, I've got to go back and disassemble everything and check it out again.

For the rest of the weekend, I rod my buddies KTM 450sx.

Couple of things, sorry for long post:

1. Vibration - non-issue. This was one of the more suprising things for me. At idle it shakes and vibrates pretty good, but once you give it some throttle it smooths out pretty nicely. I was plesantly surprised. Even Randy commented on how smooth it ran.

2. Temp: When was able to ride it in the dunes, 60-70 deg weather, she ran around 225 temp, higher than I'd like. I'm going to go back to using a spal fan, I took it off for the trip.

3. Kick starting - super easy, compared to my high compression stock bike, this was a non-issue as well.

4. THere is no better handling chassis on the planet than this one... hands down was awesome.

Next steps are to get it back running correctly, now that I'm not in a hurry I can take my time and see what I can do. You could tell she wanted more pipe, so I'm going to design another pipe and build a more mid range pipe and see how that reacts. Intake, it definitely needs more air. The stock style boot/air box are crap. I'm going to build a hand coned intake boot and really get some more air flow for the motor. I think with these changes it will be pulling 66-68 hp easily and be the perfect bike for me. I did get to see a glimpse of what she is capable off, and she's a beast.

[nico]

Teething issues like that can drive you nuts... I had the same problems on my 330 project and finally put it on the same dyno at Randy Stewart's shop. I'm sure you will get it figured out for the next trip.

After a couple changes and some time to think away from the crowds, my 330 is running way better and made 55+ hp in trail tune and pulled to almost 11k. It would have taken way too much time to get there without the dyno a/f graphs.

[DnB_racing]

still considering what you've accomplished...... I say well done!!!

ya there are a few bugs to work out but you've got the hardest part done... the rest should be almost fun knowing what's ahead

[etccb]

Stinks about the genuine honda oem cr ign which is probably the most reliable, turn key, trouble free component in motorsports.
Man I love the color and decal setup on that thing.

[sand_blaster]

You should diffently post up a few pics of it all complete like in its dune shoes.

[k7mm]

Very nice ride report Troy. You could be a ATV magazine test rider editor hahaha. I have had two trips,that I worked on my quad till the day before we was to leave. It makes for a very stressful trip.Both trips revealed that I needed to make changes and I am still not done. It has been a few years building mine too Troy.I appreciate you building this for the public to see Troy.I tried to do a build thread,but I am kinda a private person,so it really was not for me. But every ones different and it has been a blessing to see you build this. I am proud of you Troy!!!
P.S. That is so cool that your Dad went with you on your riding trip. What great times it is to enjoy these off road machines with family!!!
Keith

[troybilt]

Originally posted by sand_blaster
You should diffently post up a few pics of it all complete like in its dune shoes.

Here is some more pics... without dune shoes.. LOL!

http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/Elly1_zps9e1aef60.jpg (http://s74.photobucket.com/user/robltc/media/Elsinore%20Part%202/Elly1_zps9e1aef60.jpg.html)

http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/Elly2_zpscfeb47dc.jpg (http://s74.photobucket.com/user/robltc/media/Elsinore%20Part%202/Elly2_zpscfeb47dc.jpg.html)

[troybilt]

Originally posted by k7mm

P.S. That is so cool that your Dad went with you on your riding trip. What great times it is to enjoy these off road machines with family!!!
Keith

Thanks Keith, yes it was awesome to have my dad there... Last year was his first time back to the dunes since I was 12 years old. He had a blast on his Teryx!!

[troybilt]

Originally posted by etccb
Stinks about the genuine honda oem cr ign which is probably the most reliable, turn key, trouble free component in motorsports.
Man I love the color and decal setup on that thing.

It looked like the stator was damaged by a screw driver or something similar. It needs rewound now.

[312R1]

Ok now that you have had the pleasure of riding it, sell me the frontend back..lol


Looks bad a** bro!

[Fear250r]

Originally posted by 312R1
Ok now that you have had the pleasure of riding it, sell me the frontend back..lol


Oh Steve...trying to get back all your parts?? Haha!!

Troy, looks great buddy!! Glad to see you've finally made it to the tuning/riding part of the build!!

And...yeah, I think I see an up and coming calendar girl!!

[312R1]

Originally posted by Fear250r
Oh Steve...trying to get back all your parts?? Haha!!

Troy, looks great buddy!! Glad to see you've finally made it to the tuning/riding part of the build!!

And...yeah, I think I see an up and coming calendar girl!!


I would love to, but I'm betting Troy won't sell. Lol

[troybilt]

Originally posted by 312R1
I would love to, but I'm betting Troy won't sell. Lol

Everything's forsale Steve... LOL! :D

...but I would like to get more seat time on that front end first. I might sell it later on after I finish my own design.

[312R1]

Originally posted by troybilt
Everything's forsale Steve... LOL! :D

...but I would like to get more seat time on that front end first. I might sell it later on after I finish my own design.

Good to know.:D

The next bike I pick up has a Laeger narrow cr500 link so I'll have that.;)

[troybilt]

More ride report: (posted on the othersite as well)

i'm getting discouraged at this point, should have went with a 350PV motor.. LOL! Spent most of the day jetting this bike and have gotten nowhere its basically deja vu from last weekend at the dunes.

Biggest issue from beginning is absolutely zero throttle response, if I roll on the throttle VERY slowly and get 1/2 to 3/4 throttle, then stab it she screams... wayyyy too insanely fast for dirt. If I'm idling around, 1/8 to 1/4 throttle and stab the throttle even barely she bogs almost dies and some cases dies, I have to then let off the throttle and then slowly roll on it again to get it going. Top end jetting feels about right, no sputter pulls ridiculously hard on the top. Do these big 500's just have horrible throttle response? It has about as much torque on the bottom as an 80cc.. Maybe its not possible to do what I wanted to do.

I've got a 40.5 PWK, 180 main, DGH needle middle clip, and I've tried a 48-65 pilot jets, right now sitting at 58. I've tried all 5 clip positions. Next step is to try different needles, I don't have any others right now need to order them I guess. Should have kept the Lectron... LOL!

[hontrx265r]

I would think you could get it to run better then it is even without having it exact. Have you checked compression again or done a leak down on it? Sounds like its lean from your explanation. May have a slight water leak which could make it really hard to work with also. Again I don't know much about that motor or your setup but is ignition timing correct? Also lectrons suck so your better off without. Everyone has their opinions I like the pwk always had great luck with them halls precision is down the street from me and hes built some great motors for my friends. He says he can get more h.p. out of a mikuni. It will take time I know youll get it, but that's the nature when you dare to be different.

[troybilt]

Originally posted by hontrx265r
I would think you could get it to run better then it is even without having it exact. Have you checked compression again or done a leak down on it? Sounds like its lean from your explanation. May have a slight water leak which could make it really hard to work with also. Again I don't know much about that motor or your setup but is ignition timing correct? Also lectrons suck so your better off without. Everyone has their opinions I like the pwk always had great luck with them halls precision is down the street from me and hes built some great motors for my friends. He says he can get more h.p. out of a mikuni. It will take time I know youll get it, but that's the nature when you dare to be different.

I haven't checked compression, etc... I probably should do that again. I think it could be the pipe design of like you said a leak in the engine. There was a leak around the spark plug but I thought I fixed it.

[Skyman]

Troy, First off great build.
Second I had a 350 with a +4 crank build by Carlos with the bored 40.5 PWK. Close to your set up but yes, you do have the beast engine. With that said, I spent most of last summer with your same story. Dialing in the carb. I too have had that carb out 50 times at least! Pilots, mains, clip positions and had the same struggles you are having. Low end dog and top rpm BEAST. Going back and forth with Carlos I decided to try a new needle. He sent me 3 different. Once I changed the needle it absolutely woke up on the bottom. Quick, responsive and pulls from the get go. I would suggest trying a totally different needle.

[troybilt]

Originally posted by Skyman
Troy, First off great build.
Second I had a 350 with a +4 crank build by Carlos with the bored 40.5 PWK. Close to your set up but yes, you do have the beast engine. With that said, I spent most of last summer with your same story. Dialing in the carb. I too have had that carb out 50 times at least! Pilots, mains, clip positions and had the same struggles you are having. Low end dog and top rpm BEAST. Going back and forth with Carlos I decided to try a new needle. He sent me 3 different. Once I changed the needle it absolutely woke up on the bottom. Quick, responsive and pulls from the get go. I would suggest trying a totally different needle.

I hope you right, that is my first guess as well. I should have a few more needles to try next week. I don't have any right now. I'm hoping the pipe is not causing the problems.

[mx91a]

I second checking the timing. Not enough advance at low RPM will make it seem like a lean bog and lag or pop when stabbed from idle. The big saber just might need some more advance off idle to get going. Is the CR stator fully advanced? Maybe a CR125 CDI would be worth a shot?

[troybilt]

Originally posted by mx91a
I second checking the timing. Not enough advance at low RPM will make it seem like a lean bog and lag or pop when stabbed from idle. The big saber just might need some more advance off idle to get going. Is the CR stator fully advanced? Maybe a CR125 CDI would be worth a shot?

The CR stator is in the middle position. (the thin metal plates are still on the new stator)

[suspension101]

I've had a bad bog problem on bottom end with that same carburetor and switched to the R1368NS Needle. It's the stock CR500 Needle. It now pulls from bottom to top.

[Langbolt]

Hey Troy, What have you got your Air Screw set at ? How many turns out ?

If it's off idle to 1/8 - 1/4 throttle.....the Air screw should fix ya up.....if it runs best with the Screw more than 2-1/2 turns out then go DOWN on the pilot...if you're only 1 turn out....then go UP

Also....if you can find a DGK or DGM needle.....that'll lean out the 1/8 to 1/4 if you're rich...

Good luck.....and don't give up....no matter how frustrating this may be.

What plug are you using ? Gap ?

:D

[troybilt]

Originally posted by Langbolt
Hey Troy, What have you got your Air Screw set at ? How many turns out ?

If it's off idle to 1/8 - 1/4 throttle.....the Air screw should fix ya up.....if it runs best with the Screw more than 2-1/2 turns out then go DOWN on the pilot...if you're only 1 turn out....then go UP

Also....if you can find a DGK or DGM needle.....that'll lean out the 1/8 to 1/4 if you're rich...

Good luck.....and don't give up....no matter how frustrating this may be.

What plug are you using ? Gap ?

:D

Langbolt, the airscrew is bw. 1-1/2 turns and 2 right now, but It hasn't been running good enough to properly set to check the pilot. i.e. set idle 500rpm high and listen for it to raise as you back the screw out.

As I fix one issue I find several more. The oring that seals the dome to the head shell was shredded allowing coolant to weep into the spark plug hole. Could be causing some issues. I've got some needles coming from Pete to try and another pipe. Hopefully I'll have it nailed down what the root cause is by the weekend.

[hontrx265r]

One point for me on the coolant leak...haha knock out those gremlins

[troybilt]

Originally posted by hontrx265r
One point for me on the coolant leak...haha knock out those gremlins

Yes sir!

http://i74.photobucket.com/albums/i260/robltc/Elsinore%20Part%202/oring_zps61900720.jpg (http://s74.photobucket.com/user/robltc/media/Elsinore%20Part%202/oring_zps61900720.jpg.html)

[troybilt]

Update took the bike out to the Dunes a second trip and had nothing but problems. Turns out one of the reeds was completely missing.

Here is the video of it running, but reeds were broken/missing.

Going to send the motor to rsss396 to have him weld up the cylinder and report for more low end power. Its just too far gone to the drag side on the porting.

http://www.youtube.com/watch?v=_OH2ehYY8AU

http://www.youtube.com/watch?feature=endscreen&NR=1&v=N7kYR9zxFB4

[troybilt]

Advanced timing did help a bunch. Switched to a CR125 CDI and that woke it up a bunch until the reed broke. The big bore likes timing.

[Pumashine]

Very hard to tune with a broken reed. That really sucks. I am sure Dave will do a good job on welding your cylinder. I wish I knew more guys like him with the BB experience.

[troybilt]

Very hard to tune with a broken reed. That really sucks. I am sure Dave will do a good job on welding your cylinder. I wish I knew more guys like him with the BB experience.

yes I'm pretty stoked to see what Dave can do. I've got a renewed enthusiasm for my bike now. I was about to trade it for a KTM SX...

[Pumashine]

My saber cylinder was sent to a company that builds aluminum sleeves. They were sent the port layouts as well. According to them they have never seen a CP Industries port map. In other words they have never sleeved a saber. This is the biggest/most economical sleeve building company in the U.S. The 95mm bore will be bored out to give enough thickness for the 90mm sleeve that is inserted. With port timings changed for mild riding your low end becomes much more stable. Your pipe should work fine. With all the jetting to try and tune a race motor it gets infuriating to say the least. This was the case back when I bought a used CT410. I did not read the fine line on the website that stated "Not a dependable duner" So I found out the hard way. Spent $2500 and sold the cylinder for $200.

[troybilt]

Is that LA Sleeve? I think Dave is sending my cylinder to Millenium to remove the nikasil, then they will weld up the ports. Once that is done Dave is going to set the port shapes and heights correctly. I don't think he's doing a re-sleeve on this one, but I could be all wrong. Not doing the full smallbore Saber you speak of.

[etccb]

Now a broken reed.. Enough bad luck already. It is cool that you are going to go this route and finish elsinore. It needs and deserves to get there. As far as a 4poke goes the ktm sx would be a good one.

[Motofool250r]

Is that LA Sleeve? I think Dave is sending my cylinder to Millenium to remove the nikasil, then they will weld up the ports. Once that is done Dave is going to set the port shapes and heights correctly. I don't think he's doing a re-sleeve on this one, but I could be all wrong. Not doing the full smallbore Saber you speak of.

Troy millenium plated my cylinders, they also welded my cracked puma cylinder.

[Pumashine]

I don't think he's doing a re-sleeve on this one Yes, I talked to Dan and he explained what you were doing as well as reading the thread. Too keep cost down you are using the motor you purchased and changing port timings by filling with weld and port heights changed. If you start with a new motor you can go smaller bore and increase crank stroke to get the same power. The sleeve on mine is to change port heights without welding. I don't remember the name of the company that specializes in aluminum sleeves. The cost on the motor will still be under $3K.

[mx91a]

http://www.advancedsleeve.com/ makes the aluminum sleeve for the OEM 250R cylinder is that the company?

[troybilt]

Yes, I talked to Dan and he explained what you were doing as well as reading the thread. Too keep cost down you are using the motor you purchased and changing port timings by filling with weld and port heights changed. If you start with a new motor you can go smaller bore and increase crank stroke to get the same power. The sleeve on mine is to change port heights without welding. I don't remember the name of the company that specializes in aluminum sleeves. The cost on the motor will still be under $3K.

Yes this is what I should have done to start with, this was what Arlen was pushing me towards but in the end didn't want to mess with it, too busy.

I didn't know what I had when I bought the bike, neither did the previous owner. Live and learn. I think with Dave's help we can salvage this top end and keep the crank, rod, etc... all as is. The top end power from this motor is no joke. Its alot of fun once you get in the revs.

[Pumashine]

http://www.advancedsleeve.com/ makes the aluminum sleeve for the OEM 250R cylinder is that the company?Yes, thats it. Porting maps for all the CP Industries are available to your dealer you get your cylinder from. The builder sends in the specifications and map and they program a sleeve to be machined. Bore out your cylinder and press the new sleeve in. Goes back to the builder and he finishes his end of the port work. Then off to Millennium.

[troybilt]

Yes, I talked to Dan and he explained what you were doing as well as reading the thread. Too keep cost down you are using the motor you purchased and changing port timings by filling with weld and port heights changed. If you start with a new motor you can go smaller bore and increase crank stroke to get the same power. The sleeve on mine is to change port heights without welding. I don't remember the name of the company that specializes in aluminum sleeves. The cost on the motor will still be under $3K.

What carb, pipe, reed cage are you planning to run? Carb is a pita, you have to press a sleeve on the intake side to fit the boot, not ideal. Wish Calvin would have cast these with a CR500 reed cage vs. the Artic Cat reed cage.

[troybilt]

Yes, thats it. Porting maps for all the CP Industries are available to your dealer you get your cylinder from. The builder sends in the specifications and map and they program a sleeve to be machined. Bore out your cylinder and press the new sleeve in. Goes back to the builder and he finishes his end of the port work. Then off to Millennium.



I have access to a tube laser. I could make some sleeves... maybe a future project.

[etccb]

Wish Calvin would have cast these with a CR500 reed cage vs. the Artic Cat reed cage.

That would of kept it more industry std for the dirt off road performance group.

[laeger400]

This is pretty damn nice. Troy you did a really good job on this thing.

[troybilt]

Thanks laeger400! Wish it ran! LOL!

[troybilt]

Well this thread didn't end like I hoped. Had dreams of a sick 500r mx bike and failed, epic... Lol. Never got past the motor issues, and decided to pull the plug on the project. Going to pick up a hybrid bike this weekend as a play bike, and start a new project with a frame I'm designing in collaboration with Jerry (white chassis). So where this project ends another begins. Thanks all for the support and help along the way, this was one of the more challenging projects I've attempted from an ATV standpoint. I learned a lot and probably enjoyed the pipe and tank design projects the most. Felt like I needed closure... Lol! Feels weird not stressing about getting this bike finished. I sold the chassis and I know it went to a good home so you'll probably see it around here in pics etc....

Thanks and bye Elly she got the best of me!!! Haha!!