Brtp4's XR250R Build

Discussion in 'Thumpers' started by Brtp4, Mar 7, 2011.

  1. Baja Ho

    Baja Ho Been here awhile

    Joined:
    Jul 1, 2007
    Oddometer:
    844
    Location:
    Central Coast, CA. USA & Cabo San Lucas, Baja Sur
    Brian

    Nice report. I have two newer E start bikes but still like my Old school XR 400.
    #61
  2. Tachedoutoffroad

    Tachedoutoffroad Mr. Parrish

    Joined:
    Jul 2, 2011
    Oddometer:
    653
    Location:
    Alabama
    Bought a KTM yet??











    Idiot.
    #62
  3. Greenbean393

    Greenbean393 Rokonbeast393

    Joined:
    Dec 8, 2013
    Oddometer:
    1
    Location:
    Red River Gorge
    I bought a 96' Xr250R about a month ago. It's in like mint condition all except on how bad it smokes.. its mostly blue smoke like a 2stroke. I changed the oil an still smokes if not worse. My questions really are how do you know what needs replaced? An how do you know it's not already been rebuild. It runs amazing but I wanna catch the problem before it blows
    #63
  4. CPAT

    CPAT Been here awhile

    Joined:
    Mar 10, 2013
    Oddometer:
    190
    Location:
    Pagosa Springs, Co
    Hey green bean, had the same bike. Other than top end job, mine turned out to be valve stem seals. On tear down, you could find the culprit by looking at which port had the most carbon buildup. I couldn't find a problem with piston/cylinder, so valves were lapped, stem seals replaced and was put back together. Sold it to a fella from moab. That was in March this year and it still is running great. Good luck.
    #64
  5. DD345

    DD345 XR guy

    Joined:
    Feb 5, 2012
    Oddometer:
    42
    Location:
    Marietta GA
    Love the thread, I have the same bikes as you. I have had my 1996 XR250R for about 10 years now with a 284 kit with stainless steel valves. And no my bike is not a purple dinosaurs any more. The bike is mostly stock beside handlebars, and a skid plate. And my 1997 XR650L which I have had only for 2 years. Just simple mods like handlebars, skid plate, and desmog. Best bike combo XR250R for the trails, and the XR650L for gravel roads. Don't sell out and get a newer bike.
    #65
  6. CoeGuthrie

    CoeGuthrie 92XR600R

    Joined:
    Jun 10, 2009
    Oddometer:
    179
    Location:
    Castle Rock, CO
    Like the XR man! I just got done doing a similar think to my 92 XR600R. These bikes are awesome machines and well worth keeping IMHO. So how do you like the USD's? I haven't been able to put much time in on mine yet.
    #66
  7. oldoval

    oldoval Frank Orator

    Joined:
    Sep 1, 2010
    Oddometer:
    1,293
    Location:
    Cedar City, UT
    Nothing to add, other than I love this build. I had a 2004 that I bought new and really enjoyed. Wish I would have kept it and done something similar.


    .
    #67
  8. Firestone

    Firestone RFVC Adventurer

    Joined:
    Oct 29, 2013
    Oddometer:
    1,409
    Location:
    OKC, OK, USA
    So BRTP after putting a couple years on the bike how is it going? Have you changed anything or did you ever work out that pumper?
    #68
  9. Brtp4

    Brtp4 Powdercoat it.

    Joined:
    Sep 23, 2006
    Oddometer:
    1,983
    Location:
    Bend, OR
    Hi Firestone.

    I snapped off the shift shaft in fall 2014, so I did another freshening on it at that time. A frame swap, another (3rd) suspension revalve, added a damper, and cosmetics. I looked hard at the possibility of swapping to an XR400 swingarm to add an inch of wheelbase, but it was not possible. Of course basic servicing...repacked bearings, loctited everything, etc. One of the Kibblewhite valves had gone bad so I went back to all OE Honda valves. No piston, rings etc though.

    Some pics:

    Oops...

    [​IMG]

    Motor out
    [​IMG]

    Cleaned up the cases in Pine Sol:
    [​IMG]

    But I still did not like the way they looked, so....

    [​IMG]

    XR400 has a longer swingarm and a better shock, but the offset is different. It would have reduced the leverage ratio and added 1" of wheelbase.

    [​IMG]

    [​IMG]

    Swapped in a 96 frame that was plated:

    [​IMG]

    [​IMG]

    Finished pics:

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Before and after:

    [​IMG]

    I have ridden the bejeesus out of it, hard. Nothing other than basic maintenance, and fixing the things I break (handguards). It does not look pretty anymore, but dirt bikes are the epitome of entropy.....

    [​IMG]

    Suspension tuning session last January:

    [​IMG]

    [​IMG]

    [​IMG]

    Fireroad bombing this summer:
    [​IMG]

    I have 32mm and 34mm Mikuni flat slides but have too busy to screw with installing them thus far. They should add some top end to the power, so that it can rev out more. But it will surely require a lot of on and off to dial the jetting as well as it is now.

    It works phenomenally, especially on singletrack. Incredibly easy to ride yet super fun, and gets along very well thanks to the 280 kit. I cannot describe how effective it is; the overall package works exactly how I hoped for. I am doing a similar build with a 2005 KTM 450, when that is done I am going to give this to my son to ride. He has been riding it a bit and it is perfect for him.

    Thanks,

    BP
    #69
  10. Firestone

    Firestone RFVC Adventurer

    Joined:
    Oct 29, 2013
    Oddometer:
    1,409
    Location:
    OKC, OK, USA
    Wonderful. Great report. I have jetting suggestions for the TM34 when you get there. Running carb with no bog. I do believe I run it rich though.

    My 250 is now down for Bruce's terrain tamers and racecraft re spring. Ordered 78mm piston and sleeve (284) from XR only. Thinking about cam but not sure. The 400 is getting more love. I have a build thread going on at thump talk.
    #70
    Brtp4 likes this.
  11. roll_it_on

    roll_it_on Been here awhile

    Joined:
    Jan 14, 2008
    Oddometer:
    196
    Location:
    Boise Idaho
    Very cool share and a wonderful bike that has been given lots of great love for sure. I purchased a 2002 years ago for my son and added the 280 kit and upgraded a few other things. He sold it off to fund a 450X that he had to have but to this day I sure really liked that little 280 as it was a real hoot to ride and would be a great trail bike for me now as I get more "mature" and heavy/high power is not as appealing as it used to be........
    #71
    Brtp4 likes this.