View Full Version : 250r build starting

07-19-2009, 12:10 AM
well i have pushed a few 70's out of the way to build my girls a new 250r for dune season starting in october, its going to be hopefully a 230 pound fully wet 300cc drag bike wanna be!!! mostly for playing in the dunes and cruzzzing vendors row in the evenings,,, i have got almost all the goodies lined up ,,, so the build begins,, with chopping the rear off the frame,,,, i started with a 85 250r bare frame. 5565

i added a couple of brackets to bolt a removable subframe on it,,, i wanted something lighter than the stock part,,, i built the subframe out of stainless steel,, without any brackets on it yet... the only things to be added will be a bracket for the aircleaner,, i will be using a +6 dura blue swingarm till i have time to build my own design,,, here is what the sub frame looks like so far,,, i am also not using the rear motormounts that are between the swinger,,, i am going to add a bracket off the frame like an 88 trx,,, so i also eliminated the stuff below the swingarm bolt,,, its just added weight!!! oh i punched a few holes in the brake pedal too!!!:lol: :lol:

i raised the subframe height a little in the rear to sweep the seat to the front a little more than stock,,, should help to keep a little more weight foward too,,, i am going to use real short bend bars too,,, i like the look and it also keeps you foward a little ,,


i found a very kool set of kx80 forks,,, they are inverted,, since i am not going to run front brakes these will work perfect,,, lighter than 250r forks and more travel,, best thing,,,,,,,,, they are only 42 mm on the top side , so i bored the stock clamps to 42 mm and slid them right in,,, perfect,,, trailing axle keeps the stock geometry too


now for a few goodies,,, RPM aluminum adjustable to 6+ axle,, complete ready to play just 9LBS!!! LITTLE OUT OF FRAME DRAG PIPE,,, CHROME CLUTCH COVER TOO

i also have a front hub coming from another member that was shaved to half of its original weight,,, should look pretty kool,,, i am going to use a marvim shaw rear shock in a no link configuration too,,, i'll post more pictures when i get it to a rolling chassis,,, i had to split 3 motors to get all the goodies i needed to build a good solid 300 cc motor,, i also sent the transmission in and had it cryrogeniticaly treated (FROZEN) SUPOSE TO MAKE IT LAST LONGER AND TOUGHER AND SMOOTHER,,, WE WILL SEE...

07-19-2009, 01:12 AM
Awesome.. The parts alone amount to a mean 250R, can't wait to see this one in its next stage.

07-23-2009, 07:53 PM
When you bored your tripples, did you have to offset the holes towards the center to keep clearance for the pinch bolts?

07-25-2009, 09:27 PM
there is plenty of room to get the bolts in,, it was bored 3 mm total .. here is where i am now... got my rear shock and mounted the forks,,
i scored a set of marvin shaw rear shocks on craigslist. so i am getting closer... i am shooting for a 1.5 to 1 shock ratio,, so i have to do a little work on the top mount... it will have 9" of smooth travel,, and 10 inches on the front,,, more than i wanted ,, but it will be chushy .

The Goat
07-25-2009, 09:36 PM
very nice Mr. Kasey...how heavy is that subframe compared to stock?

07-25-2009, 10:12 PM
its all thin wall stainless steel,, it weighs half of what i cut off,,, i incorperated the grabber into it to save weight too,,, no bolts,,

07-26-2009, 03:29 AM
Amazing work man!

07-26-2009, 07:56 PM
off to the engine room,,, i installed new bearings in the good case half and started the tranny ,, i got a few new parts from bobs to insure a smooth trans operation,, shift drum like new and a shift fork was a little worn,,, i also put a better condition 2nd gear in ... as soon as i finish stripping the other side i can install new bearings and put it together,, i drilled and tapped a couple of holes in the bench to make a sterdy motor stand,,, that way when i beat the crap out of it putting it together it won't fall on the floor!!!:lmao: :lmao: :lmao:


07-27-2009, 03:42 PM
Looks steeler Richard. Cant wait to see it in person this winter :D

07-28-2009, 12:32 AM
Made in indonesia you say? Nifty work. Fan of the allthread engine stand. Bravo.

07-28-2009, 12:52 AM
Looks steeler Richard. Cant wait to see it in person this winter :D

man i hope my whole family get a chance to come to the next version of "YOU WESTCOAST PEOPLE SUCK" :naughty: :naughty: :naughty:

07-28-2009, 01:00 AM
MAN I GOT DEEP INTO THIS ONE , more than i thought to just freshen it up,,, but wow its ready to roll now,, the second motor i split was a cream puff!! i should have split it first i guess,,, but from looking at the busted case and the outside condition i figured the inside was as abused as the outside,,, WRONG .... so i get a perfect condition clutch new plates steel instead of aluminum plates... and a perfect kicker gear with very nice rachet gear,, so i should be ready for the rest tomorrow,,, working in the garage @ 113 really takes it out of you!!!

07-28-2009, 09:19 AM
Get one of those Master Cool portable swamp coolers. I've been using one for the last three years or so. Works really well. Doesn't leak or anything. You just have to stay somewhat close to it and leave the garage door open.

07-28-2009, 09:27 AM
nice work man

07-29-2009, 11:54 PM
Gotta love the stainless :)

08-01-2009, 05:19 PM
WELL I GOT A LITTLE more done today,,, i needed to build aircleaner brackets,, rezi for the rear master brackets and a few other things before i can sandblast the frame,,, i thnk i have it all now,,, at least its setting on rubber now,,, and a trim 176 lbs so far,,,,

08-04-2009, 07:49 PM
damn that thing is really nice looking so far! Hope to see it this year at glamis. Lots of nice custom parts so far, clean work too. Good luck finishing it up

08-08-2009, 05:00 PM
that motor is sick :drool:.

08-08-2009, 05:24 PM
LOL,,, just wait,,, thats just for mock up ,,, i have not even began to make the motor sick!!! its all new inside,,, when its done it will be all new outside,,, chrome and stainless and a little poilshed aluminum,,, :lol:

08-10-2009, 11:49 PM
WELL I GOT A LITTLE DETAIL WORK ON THE MOTOR FINALLY,,, she is all ready to bolt in the bike,, as soon as i get the frame prepped and finished,,, i really didn't want to paint the motor black,,,, but it was the only way it was going to look good in the frame,,,, no other colro was going to do it for me,,,

08-11-2009, 12:02 AM
Lookin real good.

08-15-2009, 07:53 PM
wow,, i am getting to the fun part finally,,, i got all the sandblasting done,, this will be my first attempt at a 3 stage paint,,, i was going to spray the color on it tomorrow,, but someone decieded that a trip to the dunes was in order!!! so i will delay paint till monday if conditions are good!!! here is a few picts of the base coat,,, next is color then clear.... that white base coat looks very mysterious in the pictures... just wait till you see the color!!!!!

08-22-2009, 05:08 PM
well ... i think i have learned alot about neon flourecents ,,, man its a lot of work but 1/2 the cost of powdercoat,,, so here i go,, primer,, white basecoat neon paint then clear,, the base coat is by far the most important coat,, if it isn't white it isn't brite!!! i had to many shadows on the subframe,, i had to start over,,, so far all the rest llooks pretty good,,, but MAN when its out in the sun you can't see anything!!!! i love this color!!!!

The Goat
08-22-2009, 06:03 PM
pics in SUN!

09-02-2009, 09:05 PM
MORE PIECES TO THE PUZZLE GETTING FINISHED,,, hell i thought this was going to be easy!!!!! :D :D :D got the front wheel done except for final polishing,, here is a peek at the color outside,,, this is a 10" suzuki wheel, it was alot cheaper and easier to find too,,,

09-02-2009, 09:53 PM
Sweeeet. I like that. looks trick! HH

09-02-2009, 10:19 PM
man that color is awsome and bright

09-03-2009, 06:12 PM
:lol: :lol: :lol: :lol:


09-03-2009, 07:57 PM
Lets see the same pic under a black light! hehe :D
Lookin awesome! Great Job! HH

09-03-2009, 09:08 PM

09-03-2009, 09:11 PM
Looking good!!!!!

09-06-2009, 03:42 PM
today i finally just sat down and started cutting . i got the stock wiring harness all tore apart, i only needed a small part of it, even though the trike will have all the lights and more working . i am going to build a custom tail light it will have about 100 led's and it will be bright. i am still on the hunt for a 250sx headlight as thats the light of choice on this one. here is a pict of the harness left on the trike,the mess on the floor is what has been stripped off . , . i am using a prodesign deadman switch and the light switch is on the plastic vent on the side of the frame in front of the tank,,

Red Rider
09-06-2009, 04:30 PM
today i finally just sat down and started cutting . i got the stock wiring harness all tore apart, i only needed a small part of it, even though the trike will have all the lights and more working.Why didn't you just have TeamGeek rewire your stock harness for more power? :rolleyes:

Looking good Richard!

09-09-2009, 01:31 AM
so here you go 116 links of chain,, on a +6 swingarm,, thanks PDR RACING!!!! I also got a TMDESIGNWORKS chain slider for a 88trx 250r,, it fit this dura blue swinger like it was made for it,,, perfect

09-11-2009, 10:46 PM
well its on rubber and outside for a minute....


09-11-2009, 11:11 PM
Amazing work man... :drool: DANG!!! What color plastics/seat have you decided on? If its Top Secret, I will gladly wait. :drool:

09-13-2009, 06:36 PM
I love the color! I hope you put oem plastics on it. Chris d's ice bike was one of my favorites, with the yellow frame. This thing will look very clean, what exhaust setup are you going with? Very excited to see this finished! Keep it up!

I might be more keen on the yellow for a reason:lol:


09-16-2009, 12:11 AM
well i got the tail light / license plate holder done since we now have to plate and tab all off-road vehicles,, the lights tested great for brightness too,,,, with 110 led's they light up the whole garage!! and these just point backwards,they will be pretty much under the seat so in the daytime you really won't see them,,,,, i got some to point down too,,, maybe green too,,,


09-16-2009, 12:21 AM
i have been asked alot what color plastic i am going with... well,,WHITE,,,some have said black would be kool!!! black plastic looks FANTASTIC for the first week,, after it gets dirty and all those fine scratches then they look crappy to me.... besides i have an idea for the plastic thats going to shock you,,,,,,,,,,,,,,,,,,,,,,,,,,:chuckle:

also black would only make it 2 dimentional,,, i need a different color to help tie everything together,,,you see i have a white chain slider to tie in somehow,,, and white letters on the seat,, and probably the white knuckles of the riders!!


09-16-2009, 08:59 AM
I like the bright color!!! my orange is kinda florescent on my 500 but I can never get a pic of it in the sun!!! arrrgg!! looks sick K-dawg~

09-26-2009, 05:45 PM
well since generation-x didn't send me a pipe,,(thief) i had to build one,, so i got down to business today and got it done,,, so on to the next part ,, rear brakes


The Goat
09-27-2009, 12:47 AM
Kasey looking good, but you already know that.

Hope you popped that little ****** with the pipe!

09-27-2009, 09:06 PM
i am past it now..... besides someday he will get his,,,

sweet 250r.... IT HAS FIRE!!!


09-29-2009, 03:05 PM
Awesome job as usual Kasey..... It's ALWAYS great to see your work!! :beer

It's funny, that color in the sun looks "photoshopped" :lol: That is one eye catching color, me likey :D

I guess one of the best thing about trikes is that you can use and fabricate and do WHATEVER the hell you want :w00t:

09-29-2009, 08:52 PM
freakin awesome trike dude!!!!!

09-29-2009, 10:39 PM
heres adifferent angle ,,,,

09-30-2009, 10:54 AM
So when are we taking it muddin?

09-30-2009, 04:37 PM
So when are we taking it muddin?

:lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol:

09-30-2009, 05:05 PM
badassss i like the LED taillight

10-03-2009, 11:00 AM
That looks like the carb off my 95 cr250. Looks like you painted it, how well does that hold up? Did you sandblast it first? And the cases and cylinder, did you sandblast them first too? That whole motor just looks sweet.

10-03-2009, 05:22 PM
I think i need a towel!! Holy trailprotrailprotrailprotrailpro that trike is SICK!! I'd give both nuts and an arm to own that...

10-03-2009, 07:12 PM
as mentioned in the begining ,,,, i built this for my girls to play on in the dunes... the carb is a stock 34mm 86 atc250r ... i used a very small diameter twist throttle on it which i hope will give better throttle control... it will have a longer throw,,, so far its looking like i am going to be 220 lbs ready to ride,, it should be done in a couple of weeks,, . i built them a couple of 70's so its time for big bikes!! kelli on the left rides a 86 250r. kasey on the right rides a 350x,,

10-05-2009, 11:20 PM
haha i wish i was in your family. my dad thinks of trikes as one thing, Multi-Purpose utility death traps. Then agian, take away the utility and you got it about right.

10-06-2009, 09:56 PM
Thats awsome man what did you use for paint on the carb and cases

10-06-2009, 11:36 PM
Sandblasted the cases painted with acrylic enamal with hardner,,, pretty simple

10-07-2009, 12:04 AM
That's an awesome build, great choice of color as well, you build some nice stuff Kasey. Can't wait to see your choice of plastic colors

10-17-2009, 11:40 PM
been busy with a few other things,,, but i did manage to pick up my plastic and start getting it mounted,, i am going to get the seat done this week and take it to work for a little shake down before halloween,,


10-17-2009, 11:46 PM
That machine is one nice machine Kasey. You're gonna have to give us a few more pics of it to drool on when you are ready.

10-18-2009, 12:49 AM
Very nice machine.

10-18-2009, 08:33 PM
well the rear fenders are an old set of maiers i painted white,, the front fender and shrouds are maier white,, i got a set of plastic off ebay ,,CHEAP but they were so nice i didn't want to cut up the rears,, thats why there are no holes in the rear fenders,, to hard to paint inside all the holes,,,
i sat down to the sewing machine today,, the wife helped me also,, we built a seat cover and a couple of flags,,, thanks to rob mosh !!! for a great seat cover thread we got it done and it looks very nice,,,, i am going to install the seat and ride this thing this week,,,

this guy
10-19-2009, 12:07 AM
great build.

10-20-2009, 08:55 PM
i am loading it in the truck in the morning,, i will set it on the scale and see where it ended up,, then a little test run .. all i have left is the headlight, and a once over on all the bolts and fastners ,, then it will be ready for a few jetting passes ,,, and some seat of he pants dyno runs....


10-20-2009, 11:03 PM
Nice!! Dig the colour!

10-20-2009, 11:29 PM
Looks great, unique.

11-01-2009, 09:43 PM
RIDE REPORT!! we went to gordons well over halloween,, got a chance to test in real world conditions.. i knew my jetting was a little fat in the bottom and mid range, so do you think i could find a pilot jet in phoenix???? hell everyone could orderit,, not a single shop out of the 10 i stopped in had one!! since the kids ride way more on the bottom end than i do i needed to get it pretty close ,, so i put the one i had which would be close till i can find one,,, WOW!!! THATS ALL I CAN SAY. the trike was awesome,, the first trip i made on it i busted the silencer off,, (to close to the tire for my weight) i just wanted to see how the jetting was on the topend,,, i think it did ok there,,, still a little rich on the mid,,, but wow it runs great, the suspension is perfect for the kids weight,, so sunday i jacked up therear shock pressure to 300 psi so i could hammer it a little,, fun,, fun fun,,, the the throttle is to small in diameter it takes to much wrist action to gass it so i will change that,, kelli was a little timid on it saturday,, being the first ride no big deal ,, sunday morning before we left i got her to attack a few big hills and use a little power to see the difference from her stock 250r and this one 60lbs lighter and 6" longer swinger,, before we loaded it in the trailer she was feeling better about it,,, so just a few details and its a full on duner!! i was looking back,, this was a 5 month long project,, i started with a bare frame,, not a complete trike,, so it was built out of my parts bins,,,

11-01-2009, 11:12 PM
Good job Richard!

That looks sharp, Looking at those dunes makes me salivate. I'll make it out there some day...

11-03-2009, 12:25 AM
That turned out excellent.

11-06-2009, 05:16 PM
Moved to top tier showcase now that it's pretty much done. :TrikesOwn

11-10-2009, 04:19 AM
Wow, now that thing is immaculate!! To say im impressed would be an understatement. I need to get out west. The dunes look far tooooo fun!

11-10-2009, 04:25 PM
Where did you get the white gas tank?

11-10-2009, 05:07 PM
its an oem tank with a coat of white paint... we are going to see how it holds up and for how long,,, i didn't paint the underside so it can still breath,,, so we will see how long it lasts,,,

11-10-2009, 09:56 PM
depends on what you used for a ground coat Kasey, I painted my tank black and it held up well... but I used a waterborn primer first, a water born primer will not let anything threw it. but the solvents still built up underneath it and I still had some bubbles but for the most part it held up well.

11-10-2009, 10:12 PM
freaking amazing

11-26-2009, 12:08 PM
Simply amazing. Love your work man!!!


11-26-2009, 01:39 PM
well i am real happy with the way it turned out. i had a chance to ride it all weekend on the last dune trip so i got a chance to really put it to the test.. the powerband is perfect for dunung very strong bottomend power with no actual band of power.. its got a very smooth transition from low to topend. the suspension turned out to be a better suprise ,the forks with stock springs and 15wt oil very nice with 10.5" of travel. the rear no link with a marvin shaw shock also worked out very nice with 11" of travel... riding it all weekend refreshed my thoughts on why i ride TRIKES!!!


11-26-2009, 09:44 PM
I'm glad to see this got put in here. Definitely top tier. And one fine, fine 250R.

11-28-2009, 05:33 PM
turned out nice,really nice.that pipe dont burn you does it?

12-11-2009, 01:42 AM
man those are some lucky girls!!awsome build.:beer

12-11-2009, 09:57 PM
turned out nice,really nice.that pipe dont burn you does it?
i need to get a few shots from the back,,, there is alot of room between the footpegs and the pipe,,, riding its actually cooler on your leg because of the air space and wind blowing on the pipe,,, pipe under the tank has very little air to help cool it and its right against your leg ... the only worry is in a crash it will be out there just waiting for you,,, so far no problems.. i also mounted it alot lower than alot of other drag pipes

i rode it all weekend and alomst forgot ot was out there,,,

12-13-2009, 12:38 AM

12-17-2009, 02:42 AM
Bike looks amazing. great build

04-04-2010, 08:49 PM
well i fianlly got around to finishing kellis 250r,, after a couple of trips out with it there were a few things i needed to fix or change. headlight is on,, and i built a better silencer,, much bigger and much quieter.. i put a turbine core out of an old fmf silencer i had in it. then changed some jetting and went over it to see if i missed anything,,, we are all going riding next weekend, so i got a little more work to get all 6 bikes ready ,,,




04-04-2010, 09:01 PM
WOW thats sick!!

04-04-2010, 09:30 PM
That turned out great.

05-16-2010, 11:16 PM
I wish my beater 81 250r looked that good.. I could make it look new again but the way I ride it it would look like it does now in a few months again I think.

05-22-2010, 01:55 PM
Wow thats all I can say, it looks amazing

08-02-2010, 12:46 AM
Whats this bad boy weigh in at?

09-26-2010, 11:43 AM
Kasey that is awsome...How long did it take you to build that.......WOW Simply Awsome.Can u help me with a good machinest?????

Russell 350X
09-26-2010, 06:25 PM
That turned out very nice. Good work!!!!!

10-01-2010, 12:51 PM
What year are those KX80 forks? I'm itching to do a 250r front end conversion to my 350x then when I saw those inverts fit in the tree's with minimal boring........I thought COOL! Now if I wanna really go inverts I won't have to shell out 500+ bucks to get a kit from Jason hall.And plus KX80 forks don't eat fork seals like the KTM forks most people use.

03-01-2011, 05:09 PM
What are the advantages and disadvantages to having a removable tail section? I can see an advantage being easier to work on around the swingarm or shock. It might able to fit in a smaller space for transportation. But wouldn’t it be a better benefit to weld in gussets instead? I’m just curious because I have my 350X down to the frame and I like the look of the removable tail section but am concerned about strength issues.

atv innovations
03-03-2011, 09:18 AM
Very nice build I like that you do all your own work!