The Official Honda CRF250R/CRF250X Thread

Discussion in 'Thumpers' started by nuggets, Jan 26, 2014.

  1. nuggets

    nuggets It's all my fault...

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  2. nuggets

    nuggets It's all my fault...

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    All 2007+ CRF250X and Cali model 250X bikes have the Air Injection System. The system injects fresh air from the airbox into the exhaust stream. Removing this should not change the performance of the bike, but it will lighten it by 13.25 ounces in my case.

    The system uses intake vacuum to power an air pump which pumps air from the airbox to the exhaust.

    This shows the AIS pump, and hoses.
    [​IMG]

    First, I cut the steel hose off of the plate the supplies air to the exhaust. I cleaned that up, and then filled it with JB Weld.

    [​IMG]

    [​IMG]

    [​IMG]

    Next, I cut the hose that gets intake vacuum to the AIS pump, and plugged it.
    [​IMG]

    Next, I pulled the AIS fitting out of the airbox.
    [​IMG]

    [​IMG]

    Finally, I used some thermoplastic to make a plug for the airbox.

    Hot soft plug
    [​IMG]

    Cool hard plug
    [​IMG]

    That is all it takes.

    The plastic I used is called Polycaprolactone. It is a thermoplastic that softens and turns clear at 140 degrees F. When hard, it is a lot like Nylon.
    http://www.amazon.com/Missing-Link-...90754212&sr=8-1&keywords=missing+link+plastic

    I carry the stuff in my trail kit when camping off of the bike, so I can make repairs to plastic parts if needed.

    #2
  3. getiton

    getiton n00b

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    Love my 2005 CFR250x. Bike is a ton of fun and I'm enjoying a whole lot more than the DRZ400 I had before.
    #3
  4. nuggets

    nuggets It's all my fault...

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    Any pics? How do you use it?
    #4
  5. nuggets

    nuggets It's all my fault...

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    Suspension rebuild on my CRF250X:
    [​IMG]

    Taking the cap off of the shock.
    [​IMG]

    I found this issue with my shock :doh. New seals won't fix this.
    [​IMG]

    The nick means I need to replace the rod. That's a $250 part. NOPE!

    I ordered a $60 CRF250R shock off of Ebay to get the part I need, and I'll swap the valves from this shock into it when it gets here, and build a new shock from all the best bits.

    Here is what a shock looks like in pieces. They are not hard to disassemble.
    [​IMG]

    Since I had to wait for parts for the shock, I started on the forks.
    [​IMG]

    [​IMG]

    After, I got the forks buttoned up, I finished the shock.

    Here, I am getting ready to put the X valving onto the R shock shaft. Note the new bumper.
    [​IMG]

    Shock internals ready for installation into the shock body.
    [​IMG]

    And the shock installed.
    [​IMG]
    #5
  6. TedG540

    TedG540 Been here awhile

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    Here is mine.

    <a href="http://www.flickr.com/photos/tedg540/9205752882/" title="CRF-250X by tedg540, on Flickr"><img src="http://farm3.staticflickr.com/2872/9205752882_639718a409_c.jpg" width="800" height="450" alt="CRF-250X"></a>
    #6
  7. nuggets

    nuggets It's all my fault...

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    That's a sweet ride Ted. Is that an 07? I see it has the AIS system on it.

    I had a massive MBS flare up yesterday, and this thing followed me home:
    [​IMG]


    So before I get too distracted, I have to finish up my CRF.

    Here she is:
    [​IMG]

    [​IMG]


    I am working on reinstalling the wiring harness, then I will just need to install the fuel tank and plastics, and fill her with fresh fluids. Almost ready to rock.

    I was going to plate the CRF and use it for my small bore adventure bike, but the arrival of the KTM has changed that plan. Looks like the CRF will be my singletrack bike.
    #7
  8. MartiniUp

    MartiniUp Long timer

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    Nugget, that shock will be much easier to remove if you re-install the upper shock bolt as it came from the factory. Your photo shows yours is in backwards. It will have interference from the reservoir as it is now. Not a biggie, just one of those little detail things.
    #8
  9. nuggets

    nuggets It's all my fault...

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    Do you mean the bolt where the top of the shock attaches to the frame as seen here?
    [​IMG]

    There is only one way to install it. The head of the bolt is shaped, and the frame is machined to hold the bolt head.
    #9
  10. Krazyjohnny

    Krazyjohnny Been here awhile

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    Looks great. We are working on one currently as we'll. this will be my second.
    #10
  11. TedG540

    TedG540 Been here awhile

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    It's a 2012. The AIS is long gone.

    Did you make any changes to your valve stack? I picked up a used shock/forks, to test my rebuilding skills on. This is a timely thread.

    Speaking of orange, I hope the X does not get jealous.

    <a href="http://www.flickr.com/photos/tedg540/12253889643/" title="KTM350exc-1200 by tedg540, on Flickr"><img src="http://farm8.staticflickr.com/7397/12253889643_2a274e7b42_c.jpg" width="800" height="554" alt="KTM350exc-1200"></a>
    #11
  12. nuggets

    nuggets It's all my fault...

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    I didn't change the valve stack. I just swapped the X valving onto the R damper rod.

    I did end up having to get a machine shop to fix the threads on the damper rod. They are deformed from the factory. The service manual said to use a die to clean them up, but it wasn't working.
    #12
  13. TedG540

    TedG540 Been here awhile

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    Where in VA are you located?
    #13
  14. nuggets

    nuggets It's all my fault...

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    Down by the mouth of the Bay. I'll be living off of one of my bikes up in the National Forest for a week this summer :evil
    #14
  15. Gonzo_Matt

    Gonzo_Matt Random Hero

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    Here's mine. 2004. It's plated, pro circuit TI pipe, some other goodies. I came off a WRR to this, and wow, it's night and day. I'm stoked so far.

    [​IMG]

    Rode some Hatfield McCoy trails in WV this week:

    [​IMG]
    #15
  16. nuggets

    nuggets It's all my fault...

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    That looks like a sweet ride. Very clean.
    #16
  17. Sledred

    Sledred Been here awhile

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    Glad I found this - I've been thinking about a 250X as an alternative to my XR650L for shorter distances but tighter trails. It 's going to take awhile to digest the info - quite an impressive list of links & information.

    Thanks guys for your efforts!
    #17
  18. hudsen8

    hudsen8 Adventurer

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    Is this really the only thread on these bikes? Such great bikes and no talk...Guess everyone is out riding hahah :D

    Well here is mine I picked up after my accident for when I'm able to start riding again

    [​IMG]

    Although I'm wanting to trade it for something street legal seeing as I can't plate this guy in Ga which is BS
    #18
  19. manstache

    manstache Flounder of ADV

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    .
    #19
  20. like2lean

    like2lean Been here awhile

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    I was wondering the same thing, but for plating a bke in OK, might be a hassel.
    #20