250-500cc WR 250 built thread

Hi there,

i m about to build my own WR250, based on a 1993 Engine, 1995 Frame with 2004 plastics.
After 2 years on a 2013 WR125 (most unreliable Bike ever owned!) i need a reliable 2 stroke enduro bike.

Every time i had a chance i bought husky parts to make sure i don t have to wait for spares when i might need them, also i did rebuilt a WR250 for one of my neigbouhrs and still have a few parts left over...

Took the engine apart- Big end bearing failure...

Clutch looks good!



Big end bearing doesnt...

I already ordered and recieved a KTM 250 Conrod, Öhlins shock, took the cyclinder to a shop to get re- hohned... thursday i ll get some öhlins forks from a yamaha wr250... so hopefully the bike will be complete by mid august.

couple of questions:

how big is the difference in power output from the pre 99 engines to the newer ones? more torque?
which exhaust pipe will work- do they fit through all years apart from the mounting brakets?

Suspension finally arrived!

dang, the ohlins ought to be a nice upgrade!

Not sure which bodywork i m going for but i prefer the 2000 onwards plastic kit over the newer ones.

I'm following , I like the yellow and blue also.

New Chinese Radiators just arrived...

I had to repair the crankcase with epoxy as the conrod did damage the surface. Its more a cosmetic repair, but i really prefer both cases to be identical and smooth.

This is relevant to my interests...

Humm should be freaking awesome when done!
Keep up the good work.
Getting Ohlins shock too? what bike you salvage that from?

I ve got 2 öhlins Shocks, First one is of a 1993 TE610 second one of an 1999/2000 WR250- but i m still not satisfied- i would love to get one with seperate high -lowspeed damping...
Forks are from a YZ426F, will see where to get some triple clamps.
Ran into a problem today: the subframe i bought is not the correct one... I need the new, narrower version but got the old style subframe... So it looks like i have to cut and re weld them.

Ohh it gets juicyer!
Keep us posted about the subframe.
Nice info on ohlins will keep eyes peeled for yzf426 forks just for the sake of it.

Will update here as soon as i got some news.
Tomorrow i have to repair my lathe as i have to get the KTM conrod machined to match the WR crank.

250 conrods are still available, friend bought a pro x one not long ago.

I Could not find one when i was looking for a replacement... So i went for the 2000 250sx.
Got my vice ready for it now- just need some time to do it.

What needs too be done? I would avoid any thing that disturbs the hard chrome, like drilling a hole in the small end for lubrication.

The Bing end bearing Pin needs to be shortened- not a Big Deal really. I ve done that with a TE610 Pin already (fits from mercedes CDI engine ;-) ). To run a old husky you have to think out of the box sometimes.