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CR250R-3 winter strip down, rebuild and revamp [message #260959] Sun, 06 November 2011 19:37 Go to next message
Gazk is currently offline  Gazk   United Kingdom
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(8) Moto2 GP Racer
Hey guys, the motocross season is finished for the year, ready to open again in March next year. So I've decided to get the bike in the best possible fettle I can for (hopefully) a good season next year.

So I started by getting my suspension fully rebuilt by Johnny Gaskell at Revs in Halesowen.

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/1c929a75.jpg

Forks freshly removed. Please excuse the clutter..

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/249da062.jpg

Rear shock unit just removed (and cleaned up a bit)

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/1b5aed71.jpg

Rear shock back from rebuild (and forks too). Not a lot to see on the forks, but see a hint of a red spring on the rear shock. Had forks and rear shock re-sprung. John weighed me with my gear and judged that the springs previously installed weren't tough enough for me and recommended the upgrade. Suspension re-valved for nice plush action so should handle like a dream now... Well for motocross anyway Laugh And a little bit of Revs advertising too.

More to follow soon when I get round to changing other stuff. Got some pretty nice plans for the bike, and quite a few things need replacing for mechanical surety so there'll be a few updates for you Thumbs Up

[Updated on: Sun, 06 November 2011 19:37]

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Re: CR250R-3 winter strip down, rebuild and revamp [message #260960 is a reply to message #260959] Sun, 06 November 2011 19:52 Go to previous messageGo to next message
steve p is currently offline  steve p   United Kingdom
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get yourself a good magnifying glass Gaz Thumbs Up i didn't know they made engines that small Laugh hope it goes well for ya Thumbs Up
Re: CR250R-3 winter strip down, rebuild and revamp [message #260963 is a reply to message #260960] Sun, 06 November 2011 21:05 Go to previous messageGo to next message
SP2 Riley is currently offline  SP2 Riley   United Kingdom
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(19) John Surtees
top job gaz you cant beat getting the suspenders sorted Thumbs Up

got y sp2 springs of him Wink knows his stuff smile

[Updated on: Sun, 06 November 2011 21:06]

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Re: CR250R-3 winter strip down, rebuild and revamp [message #260964 is a reply to message #260963] Sun, 06 November 2011 21:11 Go to previous messageGo to next message
Quazi is currently offline  Quazi   United Kingdom
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(22) Giacomo Agostini
Has to be done this time of year bud, naff all else happening. smile Thumbs Up
Re: CR250R-3 winter strip down, rebuild and revamp [message #260966 is a reply to message #260964] Sun, 06 November 2011 21:25 Go to previous messageGo to next message
SP2 Riley is currently offline  SP2 Riley   United Kingdom
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(19) John Surtees
Quazi wrote on Sun, 06 November 2011 21:11
Has to be done this time of year bud, naff all else happening. smile Thumbs Up



nice in the woods Laugh
Re: CR250R-3 winter strip down, rebuild and revamp [message #260967 is a reply to message #260963] Sun, 06 November 2011 21:33 Go to previous messageGo to next message
Gazk is currently offline  Gazk   United Kingdom
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(8) Moto2 GP Racer
SP2 Riley wrote on Sun, 06 November 2011 21:05
top job gaz you cant beat getting the suspenders sorted Thumbs Up

got y sp2 springs of him Wink knows his stuff smile


Pretty much everyone I know in the sport use him as well and they praise his work so would be silly to go elsewhere.

Although me and my brother had forks are rear shocks overhauled by him and between the two of us we spent £850!! eek
Re: CR250R-3 winter strip down, rebuild and revamp [message #261388 is a reply to message #260967] Sat, 12 November 2011 21:11 Go to previous messageGo to next message
GIZZY BEAR is currently offline  GIZZY BEAR   United Kingdom
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(14) Eddie Lawson
Johns done three of my bikes, the blade, gixer and an old yz250, was well chuffed with the results on all of them, guesses your weight by looking at you pretty well too Laugh .

May get him to give the KTM the once over Grin .

bear Grin

[Updated on: Sat, 12 November 2011 21:12]

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Re: CR250R-3 winter strip down, rebuild and revamp [message #262149 is a reply to message #261388] Mon, 21 November 2011 21:48 Go to previous messageGo to next message
Gazk is currently offline  Gazk   United Kingdom
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GIZZY BEAR wrote on Sat, 12 November 2011 21:11
Johns done three of my bikes, the blade, gixer and an old yz250, was well chuffed with the results on all of them, guesses your weight by looking at you pretty well too Laugh .

May get him to give the KTM the once over Grin .

bear Grin


Gave the suspension a shake down at Apex in Worcester couple last weekend. Was seriously impressed. A lot more confident through the corners and really railing the berms and skying the jumps. Fantastic work.

Once I've got my girlfriends bike back together I shall be cracking on with this rebuild smile
Re: CR250R-3 winter strip down, rebuild and revamp [message #264424 is a reply to message #262149] Thu, 12 January 2012 22:58 Go to previous messageGo to next message
Gazk is currently offline  Gazk   United Kingdom
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Righteo.. Rebuild started in earnest now!! Been busy fettling in between work and training, got a couple weeks to get it all in shape, February will be practice month and racing starts in March so really need to pull my finger out and get this beast back in shape!

So, this is what I'm starting with:

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/d7e5b0c8.jpg

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/b08dfa52.jpg

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/a6d7f940.jpg

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/331f61c6.jpg

After half hours bolt wiggling:

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/6c802f04.jpg

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/c0d12701.jpg

Head stock bearings cleaned up and regreased:

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/0035c403.jpg

Might seem silly but I tried to cut corners and save time, so I left the wheel and forks in, undid the top clamp and just lowered the stem through the head stock. but obviously it kept rolling away!! And I felt like a tit trying to juggle the front end and find something to prop it up with. Lesson learnt...

A bit more stripping:

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/d40ff477.jpg

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/937a3799.jpg

And that's as stripped as far as needs be. Swing arm graphics removed in anticipation of delivery of new plastics and graphics. It had a full engine rebuild 5 race meetings ago so it should be plenty strong. I'll drop a new piston in after practice month ready for racing though Thumbs Up

Rear shock linkage removed to replace all the bearings:

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/e33e46a1.jpg

A bit grubby, but it'll be shiny clean for when it goes back together Thumbs Up

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/69a35da4.jpg

All other bearing races removed with little difficulty. The one on the left is the general shape of all the other races once removed, but the one on the right was completely seized in and I had to chisel it into halves to get it out. What a pain in the arse that was! Thumb Down But nevermind, the linkages are all ready to receive new bearings and seals now. Also replacing the top bearing in the shocker as well, seemed false economy to change all the bottom bearings and not the top one..

Re: CR250R-3 winter strip down, rebuild and revamp [message #264425 is a reply to message #264424] Thu, 12 January 2012 22:59 Go to previous messageGo to next message
Gazk is currently offline  Gazk   United Kingdom
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(8) Moto2 GP Racer
Ok.. so now it's time for shiny trick bits Wink

Old crap:

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/009c41f1.jpg

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/4e3685e7.jpg

Shiny new:

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/d11a2658.jpg

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/8ac9bb24.jpg

Anodized red RFX Flexi levers. Designed to bend back on themselves rather than snap off Thumbs Up

More old crap vs new shinies:

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/65865cbe.jpg

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/055fd217.jpg

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/4673d700.jpg

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/612257a9.jpg

All work undertaken under the watchful eye s of Barmy Ben Wink

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/2bb7c4bf.jpg
Re: CR250R-3 winter strip down, rebuild and revamp [message #264426 is a reply to message #264425] Thu, 12 January 2012 23:02 Go to previous messageGo to next message
Gazk is currently offline  Gazk   United Kingdom
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You'll notice that my time lapse photography is a bit of a failure as well because I couldn't wait to fit the trick bits. So you'll see my "start out" pictures already have the trick bits fitted Laugh

So parts being waited on:

New plastics
New Graphics
Seat cover
Lower shock linkage bearing and seal kit
Upper rear shock bearing
New grips
Front and rear brake pads

And that's it for the time being, just some cleaning to do and then putting the beast back together! Thumbs Up

[Updated on: Thu, 12 January 2012 23:09]

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Re: CR250R-3 winter strip down, rebuild and revamp [message #264427 is a reply to message #264426] Thu, 12 January 2012 23:12 Go to previous messageGo to next message
drew70 is currently offline  drew70   United Kingdom
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Keep up the good work its taking shape nicely Thumbs Up
Re: CR250R-3 winter strip down, rebuild and revamp [message #264428 is a reply to message #264427] Thu, 12 January 2012 23:36 Go to previous messageGo to next message
Kermit is currently offline  Kermit   United Kingdom
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(22) Giacomo Agostini
don't worry about the time lapse there's plenty of pics to keep my attention Thumbs Up

Looking good especially the chain which transforms that area. Don't you usually oil mx chains?
Re: CR250R-3 winter strip down, rebuild and revamp [message #264524 is a reply to message #264428] Fri, 13 January 2012 23:10 Go to previous messageGo to next message
pecker is currently offline  pecker   United Kingdom
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looks like you have been very busy gazk, and its paying off, looking good mate Thumbs Up

and its not all show, some proper maintainance going on there too Thumbs Up as you have to on a competition machine

my cr shock linkage bearings need looking at too. must get my finger out

keep the pics coming Thumbs Up

[Updated on: Fri, 13 January 2012 23:10]

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Re: CR250R-3 winter strip down, rebuild and revamp [message #264831 is a reply to message #264524] Sun, 22 January 2012 21:17 Go to previous messageGo to next message
Gazk is currently offline  Gazk   United Kingdom
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pecker wrote on Fri, 13 January 2012 23:10
my cr shock linkage bearings need looking at too. must get my finger out


I don't know if you've ever done them before bud, but they are pretty fiddly. The old bearings took a bit of hammering to get them out and as you can see I had to fully destroy one race to get it out.

On that subject:

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/ee328b96.jpg

Bearing and tube in.

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/81c33106.jpg

One linkage section nearly finished. Just seals and outer cups to go.

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/e2c2d13d.jpg

And I made a wee mistake. Pressed the bearings in without putting the tube in which would not push in after. Had to press them back out and start from scratch.. luckily not damaging the races.

Front brake pads have turned up but just waiting for rears, new rear tyre, new plastics and graphics and then I'm good to go (I think) Grin
Re: CR250R-3 winter strip down, rebuild and revamp [message #264857 is a reply to message #264831] Mon, 23 January 2012 21:06 Go to previous messageGo to next message
Kermit is currently offline  Kermit   United Kingdom
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Gazk wrote
Pressed the bearings in without putting the tube in which would not push in after. Had to press them back out and start from scratch.

Been there, done that with the tube between bearings in wheels Laugh


Re: CR250R-3 winter strip down, rebuild and revamp [message #264860 is a reply to message #264857] Mon, 23 January 2012 21:26 Go to previous messageGo to next message
lloydiecbr is currently offline  lloydiecbr   United Kingdom
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Kermit wrote on Mon, 23 January 2012 21:06
Gazk wrote
Pressed the bearings in without putting the tube in which would not push in after. Had to press them back out and start from scratch.

Been there, done that with the tube between bearings in wheels Laugh



me 2 twice (slow learner)lol
Re: CR250R-3 winter strip down, rebuild and revamp [message #264861 is a reply to message #264860] Mon, 23 January 2012 21:29 Go to previous messageGo to next message
RWB929 is currently offline  RWB929   United Kingdom
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lloydiecbr wrote on Mon, 23 January 2012 21:26
Kermit wrote on Mon, 23 January 2012 21:06
Gazk wrote
Pressed the bearings in without putting the tube in which would not push in after. Had to press them back out and start from scratch.

Been there, done that with the tube between bearings in wheels Laugh



me 2 twice (slow learner)lol


Glad I'm not the only one Laugh Laugh
Re: CR250R-3 winter strip down, rebuild and revamp [message #264922 is a reply to message #264861] Wed, 25 January 2012 21:35 Go to previous messageGo to next message
Gazk is currently offline  Gazk   United Kingdom
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I feel a bit better now guys, thanks Grin Thumbs Up
Re: CR250R-3 winter strip down, rebuild and revamp [message #264924 is a reply to message #264922] Wed, 25 January 2012 21:37 Go to previous messageGo to previous message
Gazk is currently offline  Gazk   United Kingdom
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a new dirt digger too:

http://i968.photobucket.com/albums/ae167/gaz_kelley/CR250%20winter%20rebuild-revamp%202011/d1eb3e6f.jpg
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