New build...

[D Bergstrom]

So, this build really started about two years ago. I wanted to upgrade the suspension on my 86 250R and really wanted a no-link rear setup, but just didn't have the money, so just went with a new rear shock built to my specs and long shock front suspension. Was a big improvement, but still wanted it to work better. About 6 months ago I noticed my frame was starting to look a little worse for wear, needed some repairs, plus the sub frame has been tweaked since I bought it in 2005. Decided it was time to just bite the bullet and do what I wanted to do in the first place:

http://i40.tinypic.com/8xq93q.jpg

[D Bergstrom]

The picture is of my new Lonestar no-link frame, DC4 swingarm, and +2+1 stem. I also got a set of DC-pro nerfs and heel guards, but didn't take them out of the box for a picture. Have been selling parts off my 250R that I don't need for the last few months, I have also bought a few other odds and ends for this build, will get pics of that stuff as it get installed. Plan on using my existing front suspension (Teixeira Tech a-arms and Motowoz shocks) and will be getting a new rear Motowoz shock built. Need to get all the suspension on the quad so I can measure to get the specs I want to run for the shock. next will be sending stuff to powder coat, then final assembly. I see this taking several months to get done.

Time for me to vent some now about Lonestar. As you can tell from the pic, both the frame and swingarm are bare. Swingarm was supposed to be bare (Want to have the a-arms and swingarm match, so planned on having them done locally.) but the frame was suppose to be Honda Red, Lonestar didn't powder coat it! Even my invoice had the frame was to be red, looks like they need to work on their quality control! Also, they didn't include the head stay! Need to call them on Monday and see whats going on.

Anyway, as this build progresses, I will post some updates. I will get some better pics at the end of the weekend.

Doug

[red88r]

Can't wait to watch this come along!

[troybilt]

This is going to be an awesome build. I know you've been wanting a new LSR frame for awhile now, glad you finally got one and going forward!! Congrats...

[danhung11]

Very nice Doug, looking forward to this one. Did you ever hear anything about your silver fullbores?

[D Bergstrom]

Thanks guys, I know I have ALOT of work ahead fo me, but can't wait until its done!

Dan, the order I placed for Fullbores ended up being cancelled. The distributer of the guy I ordered them from would not keep the order since Fullbore would not give a clear date on when they would be ready. I then called Fullbore to talk to them, and they basically told me try back in January, they might know by then when they will produce more, didn't really seem to care one way or another about getting me a set of plastics. At that point, I figured screw Fullbore, they don't deserve my hard earned money...

Really wanted to go with Silver plastics, but my white Maier's are still in great shape, so they will work just fine.

Doug

[norcalduner]

Just curious .... what are you planning to use for skid plates ?

[D Bergstrom]

For skid plates, I ordered a Pro Tech Fabrications stainless steel frame skid and a PRM swingarm skid. I called PRM a couple of months ago and asked about them making a "custom skid" for a no link swingarm, just wanted them to make a standard 88/89 without the linkage box and extend the skid flat along the entire length. When I called PRM, they actually had what I wanted in stock. I guess he gets a couple of requests a year for no link swingarm skids, so he builds a couple and once he sells them he builds a couple more, always tries to keep one or two in stock.

I already had the frame skid when I got the PRM skid, should of asked if PRM would make a frame skid for the lonestar frame, but didn't think about it at the time. I will see how the SS skid works out, if I am not happy with it, may call PRM to see what they can do for me.

Doug

[HAYESTRX250R]

Eager to see this come together.

[D Bergstrom]

Worked on mocking stuff up some today, ended up getting frustrated and stopped. First thing, no tab on the subframe for the rear of the airbox, another quality control issue for Lonestar. Another thing to add to the list for tomorrow's phone call. Second was I switched to a 450R rear brake system. The 450R caliper sticks up furtherthen the 250R one and it is hitting the airbox before I get the swingarm compressed to where I want it. Wouldn't be a huge deal, but I already sold the 250R stuff, I knew I should have kept it just in case! Arghhhhh Oh well, looks like I will be buying another 250R caliper, brake hub, and rotor. After That I decided it was time to quit for the day.

Attached a couple of pics of how everything sets right now, was trying to measure the compressed length of the rear shock then had the above problems. The pieces of wood are drilled to mimic the compressed length of my front shocks. You can see the Pro Tech Fabrications no link air box I bought a few months ago. Expensive, but it is a well made piece, just a bit heavy though. I also swapped to 450R front spindles, hubs, and calipers. As you can tell, the upper a-arms and subframe are chrome. Plan on the main frame to be red, then the lower arms and swingarm will be gloss black.

Doug

http://i41.tinypic.com/1z2n874.jpg

http://i44.tinypic.com/25rm55k.jpg

http://i40.tinypic.com/25swyvr.jpg

[jwags13]

Great start man!! I have been saving my money for over a year now for my 1st build ever and i have been leaning toward a lsr mx chasis with a no link swinger with the elka stage 5 shock. So i cant wait to see how you like yours when its done.

[D Bergstrom]

Well, finally have something to update. I ended up sending the subframe back to LSR back in December. They stripped, welded on a airbox tab, and rechromed. Had it back by the end of December. Also got a headstay from them. They said they would powder the frame for me also, but I would have to ship it back to them, then get it shipped again to me. Figured it would be easier to have my local place do it. I am actually glad they didn't powder it, because I changed my mind on the color!

Below is a pic of eveything I got back from powder today, well, the big stuff anyway, had some small parts done also. Snail Motorsports in Vegas has done powder coating for me for a few years now, always do a great job. I ended up going with blue instead of red, I am very happy with how it turned out.

http://i43.tinypic.com/1195dl4.jpg

[D Bergstrom]

Last pic for now. (I didn't say it was a big update! haha) Had Jason over at FW Carbon get me some Titanium bolts. Got the a-arm and swingarm pivot bolts a while back, those are what started everything! I saw on another forum that Jason said he could get about any Ti bolt you wanted, so after looking to see what would be the heaviest bolts, I decided to get motor mount bolts, plus a few others. (Banjo bolts and grab bar bolts.) they look so nice, I had to take a pic! Now I have to figure out what other Ti bolts I want.

http://i44.tinypic.com/es6irm.jpg

[D Bergstrom]

That's it for now, I have already started bolting some parts to the frame, just little stuff. (Stem bearing and seals, rubber holders, etc.) Can't really get to far, my garage is a mess with to many projects and I have no room to start going on this one! Still waiting for a few parts also, biggest one being new heims for the lower a-arm. (I damaged one removing them for powder.) Once I get those, I can at least get it close to a rolling chassis to move it around if needed.

Another big part is my rebuilt crank, been waiting for it to get back to me, but taking longer then expected. Hopefully won't be to much longer, then I can at least assemble the bottom end.

I realy hate this point of a build, seems like it will be forever before I can ride her again!!

Doug

[87TRX310R]

Do those TI bolts have cut or rolled threads?

[dustinshuler]

Man, I cant wait to see this build unfold! Thanks for sharing! I just wish more people would share their builds. haha

[danhung11]

Frame looks very nice Doug! I'm with Dustin, wish everyone would start build threads. They are some of my favorite to lurk on... Haha!

[D Bergstrom]

Thanks guys, I just wish I could be done already, I hate waiting for stuff!


Originally posted by 87TRX310R
Do those TI bolts have cut or rolled threads?

No idea. Best bet would be to contact Jason over are FW carbon and ask him.

Doug

[D Bergstrom]

Did a few things over the weekend, but not really much to show. Biggest thing was getting skid plates mounted up, existing holes in both the frame and swingarm skid didn't want to line up, so either had to enlarge of drill new. Frame skid also needed some trimming up near the front to clear my PRM Desert II bumper. Nothing to major, just time consuming. Also was able to get my Precision stabilizer mounted up, just need to get a shorter link arm. Still waiting on a few parts to really start assembly.

Actually, the parts I really need are for my 700XX! Doing some motor work and waiting on parts for it also. Parts should be here next week, then I can get that thing back together and have room to really get going on the 250R.

Doug

http://i44.tinypic.com/s1rndd.jpg

http://i41.tinypic.com/180r5s.jpg

[D Bergstrom]

Little more to show. Started assembly last week. Put the front end together last night. Got some LSR front hubs, but i need to order seals for them. Once I get those, then I can bolt them on and get the brakes on, front suspension will then be done.

http://i43.tinypic.com/4s0hfq.jpg

http://i40.tinypic.com/x4f347.jpg

[D Bergstrom]

Also started putting the bottom end together last night and finished this morning, got it mounted in the frame. Not really to happy with the paint on the cases. I have a Boyesen stator cover that has been in a box for months. I could have sworn the thing had a wrinkle finsh, so I bought black wrinkle paint for the rest of the cases. After I painted everything, I then pulled the cover out of the box and realized I was not even close. Plus, the wrinkle paint was a pain, didn't turn out the best. No way was I going to spend time repainting, so I just sprayed the cover the same as the rest of the motor. I was going to sand the paint of the lettering to make it stand out, but I kind of like the "ghost look". Not a perfect paint job, but who cares, this thing will be ridden!

http://i41.tinypic.com/2ajrt6w.jpg

http://i39.tinypic.com/w5zbo.jpg

[D Bergstrom]

thats all for now, plan on installing the top end on the motor tonight and should have the motor completly together by the end of the weekend. Just waiting on the rear chain slider and should be able to start assembling the rear suspension end of next week. The last thing I need is the rear shock, that still may be a few weeks.

Just wanted to show a picture of my garage, (sorry it is kind of dark) I was thinking about this while out there working this morning. I own five quads, and none of them are currently rideable! (One 700XX is in California, so I guess it doesn't really count, but I still can't ride it.) I could always take the RZR-S out, that thing is pretty fun also. :D

Doug

http://i43.tinypic.com/woit2.jpg

[ytman]

Looking good. I'm interestedto see what it takes to get from the carb to that bad a** looking air box. Is she going to be a desert bike? Don't sweat the motor paint. It looks good. I can't find any info on Pro Tech Fab. Can you point me in their direction?

[troybilt]

Looking great Doug, I'm loving that blue color frame. Where did you get that wrinkle black? That's sweet lookin'

[D Bergstrom]

ytman, yes, it will be a desert quad. Pro Tect's website is:

www.protectfabrications.com

Troy, it is just PJ1 case paint I got from Rocky Mountain ATV. It looks better in the pics then it does in person. The wrinkle was a pain, you had to spray it on pretty heavy to get a good wrinkle finish, then it was a fine line of not putting on to much or it would run. I ended up gettting some spots that look perfect, then others that were to thin so not much wrinkle, and then a couple of runs. All in all, it looks decent, but it is not perfect. My painting ability pretty much sucks anyway, I don't have the patience for it!

Doug

[jwags13]

looking good man! Any idea what rear shock you are gonna use? What length shock is best for a no link set-up?

[D Bergstrom]

Will be running a Motowoz rear shock. Ordered it awhile ago, but it is considered a custom build, so it takes a little longer.

My rear shocks extended length will be 18" eye to eye, while the compressed length will be 12.5" eye to eye. I determined the lengths by using bottomed out and extended frame heights with the 22" rear tires I use. Your shock lengths should vary by the type of tire you run. The bigger the tire, the shorter a shock will be. Should hopefully have the rear shock here in the next couple of weeks.

Doug

[danhung11]

Looks great Doug, I'm liking the blue you picked. The wrinkle black paint on the cases is growing on me. What did you prep the cases with? Also, any feedback on the Motowoz compared to the other big names?

Dan

[hartwill]

Hey, what length shocks are required and how do you like those teixeira tech arms? It doesn't look like you have ridden them but what is your opinion so far?

[D Bergstrom]

Dan, I am digging the blue also. I am glad LSR screwed up in this case and forgot to powder the frame, I think the blue will look much better then red. I didn't do much prep to the cases, as I said, I don't have the patience to be a painter! The cases were brand new in 2008 and I painted them grey back then, just wiped them down with rubbing alcohol. The grey held up really well, so this time I just took some fine grit paper I had laying around and hit the flats with that, wiped down with rubbing alcohol again, and painted. The clutch and stator cover I just wiped down and painted. Guess I will see how it holds up.

I am very happy with Motowoz. On my 450R desert racer, I have ran Elka's, revalved/resprung Elka's, Fox, and now Motowoz. The Motowoz shocks hands down are the best of the others I have tried, I can't imagine the quad working any better. I seem to get more of a "custom" setup with Motowoz then the others. (I was asked all kinds of info when I ordered.) Very happy with both the shocks and customer service from Motowoz.

Hartwill, I have been running the Teixeira Tech/Motowoz front suspension for a couple of years now, no complaints with either. I just had the uppers chromed and lowers repowdered for this build. The shocks are 20 1/8" eye to eye extended. I feel the arms are a great value, I believe they are around $550 for a set, pretty cheap for a great quality long shock a-arm. The only real pain with the a-arms is setting them up, the heims screw into the arms, so to adjust, you have to remove the arm from the pivot you want to adjust. Not really difficult, just time consuming, but once it is done, I have never had to touch them again.

Doug

[jerorski]

thats a sweet piece Doug,nice build , is that a no link airbox, i need one.

[Motofool250r]

doug did you say the a-arms and shocks were 550 for the pair?

[D Bergstrom]

Originally posted by Motofool250r
doug did you say the a-arms and shocks were 550 for the pair?

No, that price is just the a-arms. I was a little off on the price also, just looked at Teixeira Tech's website, it is $575 for the a-arms.

Jerorski, yes, no link airbox. Plan on mocking it up this weekend to see how it fits.

Doug

[bradenc19]

what kind of air box are u using i have the same frame u can buy them their high thoe just going to make mine own i gusse. Show some pic

[D Bergstrom]

Got quite a bit done over the weekend. Finished the motor last weekend, then I really wanted to see how the airbox mounted up. Took a little work but wasn't to bad, am happy with how it turned out. A little worried about clearance between airbox and shock at full compression, guess I will deal with that once I get the shock.

Next up was my new CT show chrome pipe and spark arrested silencer. Expected the pipe to fight me, but it wasn't to bad, just had to have some patience and keep tweaking it to clear everything. Turned out decent, but still going to play with it a bit more.

Also had to trim the PRM radiator shrouds for the over size radiator, then mounted up the Polaris overflow bottle. Last thing was to get the swingarm and rear suspension bolted on, no problem there.

Biggest thing now is the rear shock, just have a bunch of little stuff to do in the meantime. Should be completely finished by next weekend other then the shock, plan on calling tomorrow to get an update on it.

Doug

http://i39.tinypic.com/24l1y5i.jpg

http://i39.tinypic.com/2uigd8h.jpg

http://i40.tinypic.com/2gtoww9.jpg

http://i41.tinypic.com/2lwcck.jpg

http://i41.tinypic.com/mvqneq.jpg

[jwags13]

Very Nice!! What kind of radiator are you using? How was the fit?

[D Bergstrom]

It is a CBR, got it from ESR months ago. My only problem with the fit had nothing to do with the radiator, the lower tabs on the chassis were off some. Just had to cut a little out of the rubber bushings to fix it. Other then that, it fit fine.

Doug

[jwags13]

It is a CBR, got it from ESR months ago. My only problem with the fit had nothing to do with the radiator, the lower tabs on the chassis were off some. Just had to cut a little out of the rubber bushings to fix it. Other then that, it fit fine.

I had to do the same with my pwr rad on a 86 frame. Lookin good man, i am curious how you are gonna like the rear suspension. Any chance of a ride report once finished?

[D Bergstrom]

Got some more done in the last week or so. I am pretty much as far as I can get untill I get the rear shock. Right now I just have a 1x2 piece of wood for a rear shock. (Don't think it would handle the rough to good! haha) Anyway, I wanted to see what it looked like with the plastics on it. The last thing I did was mount the new blue beadlock rings on my DWT wheels. Without the plastics on, I thought it was a little to much blue, but once the plastics were mounted, I thought it looked pretty good.

I am a big fan of the Duncan front bumper, so I picked up a used one in great shape a while back. Only problem is, I don't think it will get used much, no skid plate, I tend to stuff the front of the quad in alot of holes! Think it will end up being a dune only bumper. I still think it looks awesome though.

My only real issue is with the nerfs. I really like the pegs, but the nerfs themselves are really wide. I wish LSR would make a XC version of these. I also bought a set of heel guards that went with them, but I would have to cut a bunch off the front of the rear fenders for them to clear. Plan on calling LSR soon to see if they can make some that don't go up as high, and maybe a XC nerf.

Doug

http://i42.tinypic.com/2me7lu9.jpg

http://i40.tinypic.com/149tqj4.jpg

http://i41.tinypic.com/zlp1cn.jpg

http://i39.tinypic.com/abnsxl.jpg

[D Bergstrom]

Couple more pics. I mounted up the PRM desert bumper and skid plates. Not sure about the frame skid, just doesn't look like it is going to last, guess I will see how it holds up. May check with PRM to see if they could do an aluminum skid for it.

This is about it for now, hopefully will have the rear shock in a few more weeks and finally take this thing out for a ride.

Doug

http://i40.tinypic.com/wvqvjr.jpg

http://i42.tinypic.com/28rp94o.jpg

[hartwill]

Sweet build.. for a skid plate check with gtthunder they make a poly full frame skid for the 450r mine fit on with No problem.. I like mine a lot better than the aluminum ones I had +it's only like $25 shipped..

[etccb]

Looking good Doug.

[dustinshuler]

Without question one of the nicest,cleanest builds on here in my opinion!! Great job!

[8686]

Having a no link quad myself, I am very impressed with how your intake system turned out. It looks great. Keep us posted as to how everything clears when you get the rear shock on. Quad looks awesome.

[D Bergstrom]

Thanks guys.

Hartwill, not really a big fan of the poly frame skids. Have never tried one, but not sure how they would hold up in the desert. The frame skids on all my quads are pretty beat up! That's why I am a fan of PRM, they can take the beating.

8686, I am pretty happy with the intake myself, turned out better then I thought it would. I will for sure report back how the shock clears once I get it. It will have no problem clearing the airbox itself, but the shock may hit the boot under full compression, just depends on how high up on the shock body the preload collar ends up.

Doug

[ytman]

Where did you go? You took us all the way to the last step then ditched us.I want to see how your intake turned out. we deserve a long term update with pictures.

[D Bergstrom]

Nothing to update because you see the last pics I posted? The quad still looks the same. Some dumba** messed up the shock measurements! (Yes, me.) I measured the compressed length, but assumed the extended length. Just went off others measurements for a DC-4 swingarm. Well, since the DC-4 was not used on the 250R frames, only the hybrid frames, when I got the shock, it was way to long. Had to send it back and have it redone. (Yes, I triple checked every measurement this time!) I have the rear shock now, just have not had time to install it and get the quad finished up. Haven't had a lot of extra time this last year. Still sitting in the corner of my garage. Probably still going to be a few more weeks, just have way to much stuff going on.

I haven't forgot about this thread and didn't leave anyone hanging. Once I have something to update, I will, just nothing has happened!

Doug

[ytman]

ok.

[8686]

And we thank you, sir.

[D Bergstrom]

So, about time for an update. I have had the rear shock for awhile, but just haven't had the time to get it finished up. The ProTect box doesn't fit great like I was hoping. Actually, the box itself is fine, clears the shock, but the shock spring will rub on the intake boot itself. Looks like I have to move the box back a little more, but then the mounts for the box won't work, so have to figure out a way to mount it. was thinking about going with one of Jerry's (laeger440 on here) airbox's that use a YFZ450 airboot. Picked up a used YFZ boot off ebay for cheap, but the fit on that isn't much better. Don't think it will work, but would need the airbox itself to confirm, but I am not going to pay $100 or so and find out it doesn't work. May have to find someone local to me who can do a little welding on the ProTect box.

Starting to get a little tired of this project, kind of wish I never started it and just kept the quad as it was, tired of seeing it just sitting in my garage with a layer of dust on it. (Especially when I think of how much money I have spent on this rebuild!) My 250R hasn't been ridden in over two years. Sad part is, I have three other quads I can ride at any time and I have ridden once in the last four months! Oh well, guess I have to keep telling myself once I do go through all this trouble it will be worth it!

Doug

[troybilt]

The YFZ boot and airbox work great on stock and CR500 link bikes, I have not tried on no-links, I forget what yours is. I have one I'm not using, I actually reversed engineered it for Jerry on the airbox's and he has a few in stock that I ordered for him, but if you want to try one I can send you mine if you pay shipping.

[D Bergstrom]

but if you want to try one I can send you mine if you pay shipping.

Thanks Troy, I may just take you up on it. It does look like the YFZ boot would give me clearance around the shock spring, but is just has a weird angle to the carb. maybe it is just weird because I don't have an airbox itself and I am just kind of eyeballing it from pictures Jerry has posted in the hydrid section.

Think I am going to mess with the ProTect box some more. Feel like for the price I paid for it, I have to use it! If I can't get it to work, then I will take you up on your offer.

Doug

[tbone250r]

Excellent build. You did the exact same intake setup I did for my Laeger no-link with pro-tect airbox. Ended up being a very clean setup

[DezSled]

I just found this build, and I'm glad I did. This is one sweet 250r....

It will be cool to see a vid hammering some whoops!

[D Bergstrom]

Yayy, an update!! To bad it is not much of an update.:( So I ended up figuring out the intake, has to go spend some money at a local fabricator.:mad: Should of just had him fab me a complete airbox from the beginning! Anyway, I had to move the Pro-Tect box back almost 2" to gain clearance around the airboot and shock, so I had the fabricator weld on some new mounts and tabs to work with the new airbox location. Also wasn't thrilled with the angle of the boot to the carb, so also had him fab up a piece of angled tubing to help with that. Haven't had a chance to go mount everything in the frame yet, but once I do, I will make sure to take some pictures and post them.

Last update is I have a new set of a-arms and stem ordered. I like the Teixeira Tech +2.5 arms, but I want to go wider and go back to a 4:1 offset wheel. Called up Laegers last week and ordered a set of long shock +4+1 arms and a +2 stem. Going to be about a month before I have them, so at that time my Teixeira arms and LSR stem will be going up for sale.

In the meantime, I have to figure out what I want to do about shocks. The Motowoz shocks are to long for the Laeger arms, so my cheapest solution would be to send them back to Jim and have him reconfigure. Problem is, I would love to get a set of 450R FOX Evol Gen 3's and send them out to be reworked for a 250R and then throw them on. Figure I nice light airshock on the front of this would be great. Probably just going to go the reworked Motowoz route, have already spent way to much money on this thing! Still, maybe someone will make me an offer for the arms, front shocks, and stem that I can't refuse! hint hint!

Will post up some pics of the intake once I have time to get it mounted.

Doug

[red88r]

Looking real good Doug! This is pretty much what I would like to do someday. Start out with a brand new Lonestar frame like my brother did years ago.

[D Bergstrom]

Got the airbox and intake setup mounted up over the weekend. Not thrilled with it, but it works. The one picture shows how much of the rear portion of the airbox I had to cut out for swingarm and brake caliper clearance at full bump. Again, not happy I had to cut out that much of the airbox, but I think the extra up travel will be worth it. The last pic shows the piece of tubing I had the fab guy make to connect the airbox to the carb. Still have a little more work to do but at least I see the light at the end of the tunnel.

Doug

http://i61.tinypic.com/33nx9ts.jpg

http://i58.tinypic.com/2eoimmb.jpg

http://i60.tinypic.com/11b4x7k.jpg

http://i60.tinypic.com/vgu6o6.jpg

[DezSled]

My roll lobo requires a extension tube similar to what you've got. I don't care for it as it makes the airbox vulnerable to caliper damage like your working on. I know bich bich bich lol. Sweet build you got going there

[ytman]

I'm bummed (not as much as you) that you had to do so much work on something that was supposed to get 'er done. Hey it's only metal. You're suspension must come up much farther than mine. You must be getting eager to run some whoops!!!

[JDiablo]

Sweet build,I cant wait to start on one of these again man...they are soo sick love the big *** gnarly pipe

[D Bergstrom]

Here is the next update. It looks done, but unfortunately its not. :( This is it "pretty" look! haha I have been looking for set of silver plastics for awhile, finally found a blem set on Ebay so I bought them, they really don't look bad at all. I got the carbon fiber stuff years ago from FW Carbon. Think the silver plastics and carbon fiber look cool, but this will probably be dune trim, for desert racing, will go back to the white plastics with my IMS 4 gallon tank. Still need to get my IMS tank mounted. The cross bar of the frame is in the way of the sump on the tank. I think just a little heat and a little reforming of the tank will get it to work, just have to get around to do it.

Got my new Laeger +4 arms mounted up, ended up just sending my current shocks back to Motowoz to get shortened. Quad now sits at 51" wide in the front, right where I want it for desert/dunes. Still have a few things to do before I can actually take it for a ride. I have an OMF seat mount that I can no longer use the knobs for, to close to the air box that I had to move back. I knew that when I moved it back, but was hoping i would at least have enough room to get a standard nut on the posts, nope, going to have to trim more of the air box. Then just need to get the motor started and the new top end broke in.

Also had a front bumper made by the same place that modded my air box. Copied the bumper I saw on ytman's 250R. Think it looks pretty good, but it was expensive. Got another made for my 450R also. Think it is a good looking bumper, thanks to ytman for the inspiration.

Anyway, thats is about it for now. At my pace, I may be able to get this stuff done and ride it by the end of the year! haha

Doug

[D Bergstrom]

Sorry, having problems with the photo hosting website, here are the pics.

Doug

http://i62.tinypic.com/281sk0m.jpg

http://i59.tinypic.com/2cpe1pc.jpg

http://i58.tinypic.com/5tt2fq.jpg

http://i59.tinypic.com/30woy9k.jpg

http://i59.tinypic.com/2n7qpt.jpg

[red88r]

Nice job! Blue and silver always look awesome together.

[ytman]

Still need to get my IMS tank mounted. The cross bar of the frame is in the way of the sump on the tank.
Can you just modify the front tank mount or fab one up to raise the front of the tank up a tad? or is it too much?

[D Bergstrom]

Been awhile since I checked, but the IMS tank is close to fitting. I think I can just heat the tank up and reform it a bit and it will work. MY last resort is to talk to Troy, I know at one time he was looking at designing an aluminum tank with additional capacity. Think an oversize aluminum tank would look pretty good on this thing.

Doug

[ytman]

I hope you have better luck than I did. I've expanded a couple tanks. Easy Peasy. Making a recess divet dent is hard. I tried to heat the bottom of a tank and make some clearance. It was tough. I had the plastic super soft and it didn't wanna stay put. Maybe if you sucked all the air out and created a vacuum it would work better. The opposite of filling the tank up with air when trying to expand it.
Aluminum tanks are way cool but a pain in the you know what. Anything that rubs on them can make a hole. When we started out racing BITD we used an aluminum tank but found that a 4.5 gallon plastic tank would make all the pits and never have any issues. Of course when I restore the BITD quad I'm going to put the metal tank on just for coolness.
I can't wait till you take this baby out. I'm looking forward to your ride report.

[D Bergstrom]

So after three and a half years, I finally got to ride this thing! Took it out about two weeks ago for a short ride. Just wanted to break it in and shake it down a little. Engine had a pretty bad bog right off idle, so I only burned a little over half a tank of gas then called it quits. Took it home and made some changes, dropped the pilot down one size and made seem adjustments to the suspension. Took it out last weekend and the thing ran great. (For a while anyway, more on that in a bit.) Bog was pretty much gone, could probably use to go down one more size on the pilot, but since it is winter, will probably wait to do that till we get seem warmer weather. I forgot how much fun a two stroke is to ride! Suspension worked great, loved the no link rear, but still have a little tweaking to do to get it perfect.

Now for the bad part. Burned up a tank of fuel and headed back to the truck to refill and take a little break. Filled the tank up, quad set for about 10 minutes, then decided it was time for another ride. Quad was a no start, kicked until my leg felt like it was going to fall off and not even a hint of firing. I have a 2001 CR250 ignition on this thing, and I have found my 250R rarely kicks back since I installed this ignition. Well, this thing was kicking back like a mother the entire time I was trying to get it started. I am guessing something failed in the ignition. (Years ago I had a stator fail while running the oem ignition and it did the same thing, kicking back like crazy.) Loaded the quad up and headed home, will probably be a couple of weeks before I can dig into it to see what the problem is. Oh well, was great to ride my 250R again though! For sure need to get it running again quickly, had to much fun riding it!

Below are the only pics I took while riding. I meant to grab my GoPro and get some footage, but forgot it, hopefully next ride.

Doug

http://i61.tinypic.com/tzbk4.jpg

http://i57.tinypic.com/168zxia.jpg

[D Bergstrom]

I hope you have better luck than I did. I've expanded a couple tanks. Easy Peasy. Making a recess divet dent is hard. I tried to heat the bottom of a tank and make some clearance. It was tough. I had the plastic super soft and it didn't wanna stay put. Maybe if you sucked all the air out and created a vacuum it would work better. The opposite of filling the tank up with air when trying to expand it.
Aluminum tanks are way cool but a pain in the you know what. Anything that rubs on them can make a hole. When we started out racing BITD we used an aluminum tank but found that a 4.5 gallon plastic tank would make all the pits and never have any issues. Of course when I restore the BITD quad I'm going to put the metal tank on just for coolness.
I can't wait till you take this baby out. I'm looking forward to your ride report.

I ended up looking at the tank a little closer and I think that reforming it may be out. Probably going to have to take the quad to a fab shop and have them notch that tube for clearance. Not what I want to do, but looks like the area on the tank is to close to the petcock to reform. Probably be a little while before this happens, as I have to partially tear the quad down for access to that tube.

Doug

[DnB_racing]

make sure nothing moved for timing.. also make sure your key is good. kick back is very uncommon in the cr ignitions, unless its so flooded, that the crank is filled with fuel???

[jms-1]

Sorry to here about the problems, but the bike looks great! I've been wanting to build a bumper like that for a while. Use to see them on old desert bikes but not so much anymore.

[D Bergstrom]

make sure nothing moved for timing.. also make sure your key is good. kick back is very uncommon in the cr ignitions, unless its so flooded, that the crank is filled with fuel???

Yeah, thats why I am 99% sure it is ignition related, my CR ignition seldom if ever kicks back. First step will be removing the left side cover and checking stuff out. I can't imagine it would be flooded, but something else to check.

Doug

[ytman]

Got cut off on the other site. I'm glad you finally got to take her out. How did your air box work out?