250-500cc WR 250 built thread

I suppose we got lucky on the 360 big end pins; the KTM model for replacement was just a bit short. Workable as is with no modifications. Have you pictures?

I still didnt had the time for the engine work, but today i tried to get the fork/triple clamps Set up with wheels, brakes etc.
The yamaha öhlins forks fit straight into the top triple clamp, the lower one needs to be machined about half a mil to make the forks fit. When i was looking for a front wheel axle i found a husky one which does 100% fit- but i dont have the right wheel- the 1993 bearings are small so i went for another yamaha Part so far...

Those are for the 99 and newer, the 92-98 are different.

Ahh that would explain it his is a 98.
Good too know.

UFO plastics finally arrived, so i started to put the Stickers on.

Has anyone a idea how much difference the old (pre99) to the newer engines make?.
Is it worth having a newer style engine?
Is it possible just to swap crank, top end and left hand clutch cover to convert the old engine to the newer one?

They are identical as far as im aware.
The 360 motors changed from top end to torque around 98 i think but 250's were unchanded.
So not much point on doing that apart from less ware on parts.
I may be wrong tho.

Bore and Stroke have changed slightly, the Reed valve differs and its so much easier to get parts...
I m not sure how much the difference is performance wise...
I checked the gaskets for clutch case and engine cases are the same- so i assume there might be a chance to swop outer cases, Barrel and crank for the newer versions.

Think you answered your own question.
Check halls odf manual for early bikes too the one your interested in and crossreferance parts see if theyre the same.

More Stickers arrived...

Sourced a subframe and some 2005 engine bits- hopefully i can upgrade my old engine with these.

i got my 1999 onwards barrel, crankshaft etc yesterday... the parts are looking good but are not interchangeable/wont fit on the pre 99 engine cases- so i have to search for those.

Love a bike build thread...popcorn ready!

Triple clamps and forks are here, still waiting for the subframe to arrive. Would like to test fit everything- i m sure i have to relocate some fasteners, got newer style radiator which have to made to fit...

You should just put that 6 speed in the newer motor.

i would if i got a newer motor... but they are hard to get- these old big chunky engines are bulletproof and not likely to break down- so there is no market for secon hand engines i reckon.

Subframe arrived today.
I test fitted the plastics but found out there is a mismatch between the side panels and Tank plastics.

Thats normally a tight fit, is your airbox fitted as thats where the lower bolt for the rear plastic mounts.
Looking good.

I see your airbox isnt fitted the rear plastic tucks up under the seat. Dont worry just yet.

Im on bored, its nice to see it all coming together keep going with the good work.

i see we ve got a lot UK guys around here...
i used to live in the uk for a while (Northants), theres quite a good offroad community there!

Is it better or worse than riding in germany?