250-500cc 2006 WR250 (re)Build Thread

Tonight I tore the bike completely down to the frame. Tomorrow it's off to get sandblasted, then powdercoated.

I'm refurbishing this bike for a friend who is mechanically challenged and performs absolutely zero maintenance on it. The only things in good shape are the motor and the frame, other than that, it's a roach.

As I go through this, I will post some pictures of the progress, as well as pictures of the carnage.

Stay tuned!!

Hoov you gonna switch to o5 plastics and seat? Anything special?

No, the guy I am doing this for doesn't want to spend any more than he has to. That said, the rear shock will be shortened to net 1" less wheel travel at the rear. I will slide the forks up a little in the clamps to compensate, after I revalve with Gold Valves and RT's specs. The rear end work will be done by TBT. Motosportz is supplying the Lectron carb and the Cannon Racecraft 42-50 progressive springs. Just got done welding the frame at the upper exhaust bracket where it was cracked, and now is at sandblaster/ powdercoater. The frame should be ready by Friday. I have all new plastics on order, including a TC449 front fender. All new cables, grips, chain, sprockets, chain guide, misc. nuts and bolts (rusted), linkage and swingarm bearings, and more, on order. Needs a pipe, anyone have a recommendation?

Funny thing, the steering head bearings were just like new with fresh grease (from when I sold it to this guy 7 years ago. I made the comment that it was the only good thing about him never washing the bike!

I'd check on eBay for the pipe there some deals on there for the PRO CIRCUIT PIPE AND SILENCER Combo for cheap. Personally I like the FMF GNARLY. I'm running a 36mm Lectron with the 3-1 rod. I like where the rod is set from Lectron and have the power jet set between 3/4 and 1 turn out from fully closed.

I think I need a new pipe.......... And nice hooked teeth on the CS sprocket, huh?

You could send that pipe out for repair. $60 i beleive they charge? Then powdercoat it clear or black or..

I would but the pictures do not show all the damage. The head pipe area is flattened and really bent and the areas at the mounts are messed up as well. I don't have the confidence that everything will line up if repaired.

I run a gnarly with the stock silencer and also have the pc full system. The gnarly makes more power down low so it's a better pipe for off road.

250-500cc My wr 250 2007.

Very nice Fredd!

my pipe looked worse and $80 later I had it back on the bike no problem just fyi. I guess its sorta good to hear the upper exhaust bracket was cracked, mine too!

The frame is home !

Supersprox- lifetime guarantee.


I traded a member the stock tank for this IMS........

Hyde Racing skid plate.

Chinese radiator hoses

Chinese radiators with EE braces

Starting the install

New bearings and seals, front and rear.

Stripping the paint off of the cases. It was already partially off so I decided to re-paint.

Stripped

Cases painted and top end going on. More tomorrow....

Lookin good!

Im doing the same process as you with my 07 WR 250. I did the motor first then rode it for a few hours and then decied to pull her to bits to have the frame powder coated black after i found a crack in the upper exhaust mount. Ive still got lots to do and its going to take a few months to get it finished. Good luck with build so far it looks like your going great guns.

I guess that is a common thread, my 93 broke some time back, funny but I never got around to fixing it
been 5 years, pipe is hanging tough