R rebuild (pics added)

[smokinwrench]

I sold my 2007 Outlaw 525 not long ago and bought a 1989 250R. It was way worse shape then I thought it was. I knew the motor was locked up. Turns out it was the left crank bearing. Other broken parts were bent axle, bent steering stem, missing tons of bolts every where, standard bolts in a few holes and thats just the stuff I can think of right now. Also welded up 3 frame cracks.

I split the cases replace all bearings and seals, inspected trans it looked good. Installed new oem clutch with cr500 springs. Replaced almost every bearing on the machine. New esr 310 with trx9 porting, 38mm pwk carb, trx11 pipe. I have tons of stuff I've bought on ebay and forums to be installed. I also have a no link roll design swinger on its way. ASR +2+1 long travel a-arms that should be here in a couple weeks. Installing Fox podium on the front and a podium X on the rear.

Problem I am having right now is I want to run a spacer plate on the reed cage. I have attempted it with stock cage, seems to move my carb to high up and to far back to be able to get around the shock area. I think I will just install the rad valve without a spacer and be done with it.

This little build has taken longer then expected. I just kept ordering parts and never got started with the build.

http://i563.photobucket.com/albums/ss78/smokinwrench/89r2.jpg


http://i563.photobucket.com/albums/ss78/smokinwrench/rrebuild2.jpg

http://i563.photobucket.com/albums/ss78/smokinwrench/rrebuild1.jpg

[ccdhowell]

Nice looking R Josh. What pipe is that, biggest freakin pipe I've ever seen on an R. When's she gonna be done? Have you cranked her yet? I have a '90 Quadracer that I need to do that very same thing to, I'm lacking the motivation to start a longterm project right now. Can't believe you traded your Outlaw on the R though.

[smokinwrench]

I realized awhile back that I enjoy building building the machines as much as I like riding them so that explains me getting rid of the Outlaw.

Pipe is a ESR TRX11. I haven't cranked it yet still figuring out the intake.

A-arms are being built and should be here in a week or 2.

It will be at Trike Rampage April 24th weekend.

[cody2]

How did your outlaw hold up for you anyways?

[smokinwrench]

I took it to the shop 6-7 times for repairs/recalls. Power was AWESOME, low end torque was out of this world. Handling was great in my type of riding. When i got rid of it engine was making lots of noise and warranty was done. Rear a-arm bushings were wore out and had been replaced. Polaris refused to upgrade it to the newer style needle bearings. So in turn I refused to keep it.

If the 525s has as good of suspension as the Predator with the power of the 525 if should be awesome. I had the option to trade mine for a 08 525s for $1,200 difference but wasn't willing to buy another right yet after having so many problems with the one I had.

[smokinwrench]

I was busy assembling this weekend. I am still missing aftermarket a-arms, twist throttle, chain, IMS 4 gallon tank. Decided to assemble it and I could install a-arms after getting the jetting done. I need time to get it broke in before the Little Sahara trip.

http://i563.photobucket.com/albums/ss78/smokinwrench/Rrebuild2-1.jpg

http://i563.photobucket.com/albums/ss78/smokinwrench/Rrebuild1-1.jpg

[Xowner]

lookin good man! hope it runs as good as it looks

[BigGreenMachine]

Thats nice! Love the Nacs graphics!

[smokinwrench]

It runs just going through the breakin jetting process now. Still have stock a-arms and a rigged throttle cable until new parts come in.

It is really rich but the power is unreal. It was starting up real nice, but I moved the needle 2 clips leaner and now it won't start cold, need a bigger pilot jet now. Starts good when warm. When I get in a pasture area that allows good traction this thing is scary fast.

Hopefully next weekend I will have the correct intake setup, IMS 4 gallon tank, LT a-arms, new chain/sprockets.

[Mosh]

Very cool...
What is up with that overflow ressy?

That is a cool idea.What type of ressy is that?

[smokinwrench]

Resy is off a predator, i thought I had this great new idea but I think Walsh has been doing it for awhile now. I like it to be up there that way I can keep an eye on it. I welded 2 small tabs on the frame in front of the left motor mount to put it there but I prefered it up there with easier runing of tube and mounting.

[smokinwrench]

I got it running good this weekend. It has unreal power and handling. My seat of the pants dyno says this thing is way faster then my 525 was. I can't believe how good it handles still being stock suspension, it will be unreal with the aftermarket long travel front end. As far as just hotrodding around it is way better then the 525 was.

I will get it dynoed this weekend to get the jetting perfect.

[xman23]

very nice r man