ATC 250RF project under way...Still at it!!!

[Jason Hall]

One for sure cure for the high 1st gear blue's Is a Rekluse clutch. I wouldn't change a thing with my CRF conversion because of this clutch. I run a 14 tooth front sprocket with a 38 tooth rear & 18" tire's. It Is the smoothest performing transmission I have ever used. All who have rode these new 4 stroke's would probably agree that they CHUGGLE when going slow In first and even second gear. My 06 TRX450 does the same thing, It sounds like the clutch basket will fly through the side cover when you bog It down In any gear. With the rekluse ALL the chuggling Is Gone. The clutch engage's Exactly the same everytime, and engage's the way you set It up, light or heavy. I also use the perch adjuster for quick easy adjustment of engagement RPM. They are expensive to buy new, but they can be picked up for around 300.00 used on ebay. I put mine In about 2-1/2 years ago, and have never had to adjust It Internally, It still has the new disc's I Installed at that time. Thanks to Derrick Adams for turning me on to this Magical setup!!! Oh yeah, I have a heavy flywheel also which helps alot. The Rekluse add's rotating mass also as It's quite alot heavier than the stock clutch part's.

Nice build Torker, looks like you did your homework!!! Can't wait to hear how you like the power delivery. IMO the only downfall to these small engine's on a heavier bike Is the roll on power. These little 250's just don't have the torque, but MAN do they Rev. If your not happy with the final result, add a big bore cylinder, and your problems will be gone. I built my boy a 87 TRX with a CRF250f, and the bike Is awesome for my boy, but with me on It I have to ride It just like a 2 stroke. Keep er hemmed up and shift.

[torker]

Thanks for the comments Jason. A heavier flywheel is on its way. But I don think it will be enough. I'm aware of the limitations on these engines, but I still wanted to give it a go and see what came out of it. The Rekluse set-up has also been studied, but it will be a last resort due to it's price, although I know it will be the right answer.
I'm heavy at 190 (used to be 211!!!) but the trike has lost a good 25 pounds from the stock weight and I still have to change the stock, gold wheels for some lighter ones, I'm not sure how much, but that should reduce overall weight, but more important rotational mass and weight. It has some smaller 20" tires (look like 18") That should help. I'm doing everything my pocket allowes in order for this to come out as good as my "pockets will allow" instead of as good as it can be, which is a great difference. I'm still comitted to this project and it will be "a rider" soon.

And please, I would hate to loose this thread because of someone elses behavior. Thanks to the Mods. for understanding that I'm not at fault. I have enjoyed a lot of projects on this Great Site, that I consider myself part of and that you guys that have been here for a long time made me feel welcomed since the begining. I'm sure there are people here enjoying this project as well as I have enjoy others.
I know sometimes we can get carried away, it's only human.

Enjoy this project and thread and feel free to comment and suggest. Those are always welcome.

TORKER.

[Jason Hall]

An X-33 Durablue axle (hollow, light, less rotating mass) would help In the rear also If you could find a good one for a decent price. The 3 wheeler Is quite alot lighter than the quad I used. I'm not trying to talk you out of doing It. I think It's a great build. If your determined you will make It just what you want. Good luck and have fun

[torker]

An X-33 Durablue axle (hollow, light, less rotating mass) would help In the rear also If you could find a good one for a decent price. The 3 wheeler Is quite alot lighter than the quad I used. I'm not trying to talk you out of doing It. I think It's a great build. If your determined you will make It just what you want. Good luck and have fun

True that...All of it!!! We must be nuts

TORKER.

[torker]

Ok guys, after about 2 weeks of work this is what we have so far:

Radiator mods are done. The 2 top outlets were straight and were hitting the top frame tube, they needed to be in a 45 degree angle, just loke the R's but these are much bigger. The bottom outlet that transfers radiator water to the water pump was at an angle that was very close, if no hitting, the titanium exhaust pipe, that one was cut and straightened. Last but not least, it needed a mounting plate so the rads were in its final place. It was made out of 6mm thick aluminum. I think it's overkill, but thy're done. Rads were moved as far forward as possible without the front forks hitting them at full lock. That was done in order to make as much room as I could to put the oil cooler in one side and a radiator fan on the other in the very near future. I think I have enough room now and everythings clears everything else.

[torker]

And then, theres the engine mounts and frame welds. I think that the aluminum engine mounts came out good. These were made out of 4.75mm (whatever that is in inches) 6061 aluminum. We try to make them look like they were "factory made". Take a look and let me know what you think.











I hope I got enough pics So, what do you think?
There's some tweeking to do, but not much as I've tryied to measure twice and cut once. Next I will tackle the most challenging part of this build: The Fuel Tank mod. I've already cut one up, just to find out plastic welding in not going to cut it. So a heat gun, patience and some more heat will do it. It's been done before...
Little by little everything has fallen into place and it's been a fun and challenging buid.

TORKER.

[Red Rider]

Torker, great build! It looks like everything is coming together nicely. Personally, I would try to find or adapt a pre-formed radiator hose to replace the one that goes around the exhaust header. It's holding it's shape now, but once it softens up from hot coolant flowing through it, not to mention the heat from the exhaust, it might just completely kink up & pinch off your coolant flow. Keep up the good work!

[audioworks04]

You might also look into a stainless steel elbow to cure the problem around the header that red rider points out. I agree that it could potentially cause a problem as heat comes into play, may also want to use some heat wrap on the header to contain the heat from it away from the coolant lines.

[torker]

I'll be looking for a cure for sure. But it's not nearly as close as an R chamber to the pump-cylinder hose, that, in most cases rubs on it. But, every little bit helps on the war against heat.
Maybe a nice elbow can be welded to the engine side and presto!!!

TORKER.

[OZQUAD44]

Torker
Coming along nicely big fella. This is my favorite build at the moment. Engine mounts look good. Once your happy with the mounts, cut the ends off your bolts that are a mismatched. You have to leave a few threads sicking out the ends so the tension on the bolt works properly, but if there are any bolts with long exposed threads that sit outside the nut you should trim them down to give it a professional look.

The radiators look great.

Do you think you could stand back a few feet so we can see the bigger picture of the motor sitting in the frame.

Cheers

[torker]

Torker
Coming along nicely big fella. This is my favorite build at the moment. Engine mounts look good. Once your happy with the mounts, cut the ends off your bolts that are a mismatched. You have to leave a few threads sicking out the ends so the tension on the bolt works properly, but if there are any bolts with long exposed threads that sit outside the nut you should trim them down to give it a professional look.

The radiators look great.



Do you think you could stand back a few feet so we can see the bigger picture of the motor sitting in the frame.

Cheers

Agreed, as soon as is out for frame painting, all the bolts will match!!!

This is as it stands right now.



I'll get a few more in the next day or two.

TORKER.

[riverrat]

Looks like it belongs there, nice job!

[Billy Golightly]

Wow that does look good. NICE!

[torker]

Thanks for the good words and encouragement fellas. I think I'll be going with the Lexx slip-on. It's the only piece missing for it to do a trial run. Other than the tank mod, that I'll be playing with tomorrow.

TORKER.

[OZQUAD44]

What's up with the project Torker? Its been a week!

I went looking for a new fourstoke donk for my Tecate yesterday, and wandered across a bike shop that specializes in restoring 80's MX machines. Talk about dool..... He said he wasn't a trike man, but he had the most pristine 84 250R underway in the shop. Looked like you could eat your breakfast off it.

The reason I went there, He had some KX and KDX motors on the shelf ready to go, but after talking to the bloke for about 1/2 and hour, he's convinced me to rebuild my existing KXT Motor. So my KXT250F project may be put on the back burner for a while, so Im relying on you for my fourstroke fix big fella..... More updates please.