Putting things in places they ought not to be (250R Hybrid Motor build)

[bkm]

Congrats. I was hoping that vid didn't end with an ambulance ride.

[fabiodriven]

Congrats William!

I was going to suggest the compression release as well. I have one on my KX500 engine. Best money I ever spent. It looks a lot like the one posted, but it goes right through the jug, water jacket and all, and it is worth its weight in gold I can tell you. You would be able to run a really short throw kick starter, it would save you so much trouble. If I can make any recommendations before your final assembly, you wouldn't regret it.

[Dirtcrasher]

Yeah, he's got a mill. He can get r done.....

[Red Rider]

I thought you were going to rip the neck off of the frame, kicking it over like that, prior to supporting the engine cradle with the jack stands. Congrats on getting it to fire. I know that must have been very satisfying! :

[Billy Golightly]

Not one of my brightest ideas and moments for sure , but hey, the point was to hear it run a little bit, and that it did.

Big thing now is figuring out what to do with the motor. I think I am going to put it in my main hernando hill climbing chassis just to be able to ride it and dial things in more. A dedicated chassis with that chrome frame and swingarm is down the road as I have pretty much no other 250R parts left to build another bike with.

[Dave8338]

it runs ! !! !

[oscarmayer]

OMG!!! i just got wood...
that sounded awesome sir!!!! dam that was some serious porn sir!!!! Dam serious!!!!! Schaaaaaa----wing!!!!!!!!

[NeverLift]

Enough said.

[Russell 350X]

Awesome job Billy!! You sure have put alot of time into it, you should be proud! Can't wait to see it at Trikefest!

[Billy Golightly]

It should be there! How good it really runs after I've had some time to play around with it is yet to be seen though

[Billy Golightly]

So I had planned to do this update before I did the running video, but I got excited and did things out of order. Lets go back and pretend it hasn't ran yet...



I mentioned in an earlier post that I had an embarrassing incident regarding the drain plug. Basically, I had the engine bolted in my frame and stand and started pouring oil in from the fill and then found it running right out the bottom because I did not have a drain plug in it . Even worse, I couldn't' find my drain plug bolt, and I couldn't remember what size and pitch I had tapped it to months earlier . I actually had to let it sit overnight because I really could not remember what I had done there for a setup...

So the following day, I tried a couple bolts, I found a tap and about 5 coarse thread bolts in a ziplock on the work bench and figured that might have been it. It fit but the threads were really loose, so I had too small a bolt, or something. Whatever I had tapped it before when it was all apart, I remembered being a good fit. But I had no idea what pitch it was. I got the thread gauge out and 1.75 seemed to fit it, but the bolt still didn't seem to start right. I was digging for a tap to cross reference with in my toolbox, when I found a large diameter bolt, with a tap tapped to it. Nothing else and it had been taped together for a long time as the tape was more like glue now. So I peeled it apart, and low and behold, I had the right one!

Problem was, as you can see, it was about a half mile too long. Trimming the length of bolts is sometimes hit or miss for me. Usually I am pretty decent at it, but this seemed to be the only one I had that actually fit what I had tapped into the cases, so I was a little anxious. I lined it up with an OEM drain plug for length, marked it, and then hack sawed the end off in the vice. I then took a very small flat file and cleaned as well as redressed the threads so it had an easy start. After a few minutes, here is what I had;

Started in nicely! Just had to be perfectly square with the bottom but that was okay, went in and back out with my fingers no problem. I then took the tap, wrapped some masking tape on it, an wrote on it, what it was so I could cross reference another bolt or easily use it again if I ever needed to.

Afterwards, it was time for me to start sourcing parts to facilitate running it. I've had a CR250 ignition with an adapter plate I've had stashed and been saving mostly specifically for this project.

Next up was getting a throttle rigged. I had bougth a new carb, but neglected to get a new cable or another thumb throttle. Luckily, I was able to procure a Magura 1/4 twist and appropriate throttle cable for the PWK from my days of the ATC500R I had built.

(I really like this picture also for some reason - It kind of symbolizes riding and fab work at the same time with the files. By the way, that first one is a fricken MACHINE. I call it my hand grinder because it cuts and works so good, you can watch the flakes of metal get shaved off with every pass fall in the area, its crazy how good it cuts on things)

Next up - I finally trimmed my carburetor boot to length using a vertical band saw. Made a good clean and nice cut. Funny story with this thing better told in some video I took with dad and I in the shop many months ago when I first started messing with the intake setup, but I actually FOUND the original piece of hose this was apart of LAYING IN THE MIDDLE OF THE ROAD on my way into town one morning. I actually saw it and thought "I wonder if that is the size of hose I need for my Rotax intake boot" stopped, back up, threw it in the bed of my truck where it rode for several days till I got back into the shop and tried it, and it was EXACTLY the right size. It was a piece of radiator/coolant line off of something, it had a spring in it to keep from getting flattened out in a bed I just pulled out in discarded, but I legitimately found the thing laying in the middle of the road and put it on the motor...

Water spigot location on my final "Good" cylinder, pretty much the same place, a little bit different than the test cylinder but essentially the same location. A little bit more of a flair out, and i got really good threads tapped in this time, it took a -ton of force to get that fitting threaded in, its not going to vibrate and fall out thats for sure...

Figuring out where to put all the electrical really is still a challenge - I basically shoved the CDI box up where the coil would normally mount and got a little bit creative by hanging the coil off of the head-stay hole here as you can see. I am not real sure how the tank will fit over that, I will probably end up doing a little bit different permanent type mount, but again I just wanted to get stuff mounted enough to hear it run. I think doing something similar in that area has the capacity to be a permanent mount. It would make me happier if the coil wire was a hair bit longer because its really stretching it to fit it in there and reach the plug now...

And finally - everything ready to go before I finally fired it up!

[onformula1]

Are you going to build a head stay?

[fabiodriven]

You know how and where to cut a bolt and also how to taper it, but one thing I always do when cutting a bolt is thread a nut on it that I can take off after the bolt is cut to straighten the threads somewhat.

[C.J]

You know how and where to cut a bolt and also how to taper it, but one thing I always do when cutting a bolt is thread a nut on it that I can take off after the bolt is cut to straighten the threads somewhat.

Yup!! Especially when cutting all-thread!

I seriously am envious of the fact that you found the "intake boot" laying in the middle of the road. THAT made the entire build worth it LMFAO


92 JP Outlaw hybrid (in progress)

87 LT265R (not much left stock)

[onformula1]

You know how and where to cut a bolt and also how to taper it, but one thing I always do when cutting a bolt is thread a nut on it that I can take off after the bolt is cut to straighten the threads somewhat.

Me too, then I clean it up on a belt/disc sander you can make it look factory.