1986 Honda 250R build*finished*

[Aulbaugh]

I bought this back in Nov of 2017(original post) and have had it on the back burner, mainly because it is in pretty bad shape and is going to take a lot! Another reason is I needed to replace the frame as this one had been cracked/repaired, foot pegs welded to the frame. Finding a nice 86 250r frame close isn't an easy thing to come by here in Tejas. There isn't much good to say about it, it has been rode hard and neglected. I have been getting some replacement parts over the year that I will need for the build and have had the motor at Yaegerb getting freshened up. I got a long way to go on it but I got the time and want to. I'll drop the new frame off for powder next week. Thanks everyone and have a good day!

[Aulbaugh]

Current fork condition: Dog crap

....Also I picked up this 86 swingarm from Red Rider for the build. The swingarm that was on it has some bad cracks by the bearing holder seals and some deep chain drag in it. Forks are going to be going out for polish and the swingarm out for powder even though I really dig the current color of the swingarm from Red Rider. The 86 carrier I got from a buddy on FB.

[Aulbaugh]

I picked up this pipe for my engine. Can anyone name that pipe?

[yaegerb]

I picked up this pipe for my engine. Can anyone name that pipe?

I can.......

[bkm]

Looks like a Selvy/Kenny Robert's pipe going by the cylinder flange.

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[Aulbaugh]

I can.......

;) I know you can!!!

[yaegerb]

Looks like a Selvy/Kenny Robert's pipe going by the cylinder flange.

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You bet brother. That is an original sonic 2 verified by Kenny and Rob.

[bkm]

You need this to go with that pipe.https://uploads.tapatalk-cdn.com/20190223/a7fbf8f92c21330b3dc9d8163a03fa64.jpg

[Aulbaugh]

Yea Brian that would be nice! I already got that old PT of yours.

[ironchop]

You need this to go with that pipe.https://uploads.tapatalk-cdn.com/20190223/a7fbf8f92c21330b3dc9d8163a03fa64.jpgWTF were you hiding that?

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[bkm]

WTF were you hiding that?

Sent from my Z958 using TapatalkI picked it up last year and was going to use it, but I'm going to run a stock cylinder instead. It's for sale! Lol

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[yaegerb]

It may be for sale doug......I haven’t decided yet!!!! Lol I kinda want it :drool:

I know what that is and she’s rowdy and purdy.

[Aulbaugh]

Got the forks and triples back from polish from the guys over at Gateway PowderCoating.
Yaegerb brought these back from the dead! They were in pretty rough to horrible shape on the inside. He built them back up with progressive springs and OEM parts.

[Aulbaugh]

Picked up the frame and motor mounts and few other small pieces this morning from Performance Powder Works. I went with Columbia Coatings Super Mirror Red for the powder.

[Aulbaugh]

Are there any replacement 86 rear caliper pistons available? I'm not seeing anything and mine need replacing.

[yaegerb]

Are there any replacement 86 rear caliper pistons available? I'm not seeing anything and mine need replacing.

You could probably scotch brite and reuse. The ones I just did for my 86 were hammered but I made them useful again.

[barnett468]

Are there any replacement 86 rear caliper pistons available? I'm not seeing anything and mine need replacing.

https://www.ebay.com/itm/ATC250R-HONDA-REAR-BRAKE-CALIPER-1985-85-250-250R-2-16/223370063701?hash=item3401e4af55:g:hq8AAOSw6X1cWhJ S

[Aulbaugh]

You could probably scotch brite and reuse. The ones I just did for my 86 were hammered but I made them useful again.

Yeah mine are beyond that. The pad ends fell off and there are some scratches in the pistons.

[Aulbaugh]

https://www.ebay.com/itm/ATC250R-HONDA-REAR-BRAKE-CALIPER-1985-85-250-250R-2-16/223370063701?hash=item3401e4af55:g:hq8AAOSw6X1cWhJ S

Yeah I saw that one Barns but I was hoping to just be able to score the pistons and not have to get the whole caliper.

[bkm]

https://www.ebay.com/itm/ATC250R-HONDA-REAR-BRAKE-CALIPER-1985-85-250-250R-2-16/223370063701?hash=item3401e4af55:g:hq8AAOSw6X1cWhJ SThat's not a 85-86 caliper.

[Aulbaugh]

That's not a 85-86 caliper.

I whiffed on that one coach. Good eye, your right.

[Aulbaugh]

I came across some NOS pistons that I am going to buy.

[Aulbaugh]

I had yaegerb blast the ugly off a some hardware and send it off to Onetrackmind for replating.

[Aulbaugh]

I had more parts go out for powder today!

[ironchop]

I had yaegerb blast the ugly off a some hardware and send it off to Onetrackmind for replating.
What kind of plating is he doing?

[Aulbaugh]

What kind of plating is he doing?

Zinc plating

[Aulbaugh]

alittle progress. more going on behind the scenes to get it closer to a roller.

[Red Rider]

Looking good. Exciting times ahead!

[Aulbaugh]

I was looking through storage and I had forgotten that when I had bought this 250r it had come with some used radiators that the PO hadn't put on. The current ones are trashed and I was looking for some replacements. Finding these were cool but I needed to make sure there weren't any issues with them. So I took them to a friend that owns a radiator shop and had him test for leaks and to make sure they were good to go. He gave them a good cleaning as well while there too. I thought I would give it a go at painting the radiators so I bought some pre painting prep and radiator paint through Eastwood. I did have to straighten some fins on the radiators before paint.(The first picture is after couple cleanings with soapy water and a toothbrush after taking it to the radiator shop)

[ironchop]

Nice rehab on the radiators



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[Aulbaugh]

A nice tool to have to torque down the adjustment nut after putting in new steering stem bearings.

[Aulbaugh]

a couple of current pictures. I got the front end on but still need the brake guides and torqued to spec . I was also able to got some NOS fork bands for the boots. I also picked up a pair of Wicked Metal Designs footpegs from Rob.

[yaegerb]

a couple of current pictures. I got the front end on but still need the brake guides and torqued to spec . I was also able to got some NOS fork bands for the boots. I also picked up a pair of Wicked Metal Designs footpegs from Rob.

Very nice! This is coming together quickly!

[Aulbaugh]

Very nice! This is coming together quickly!

Thank you sir. My powdered parts are getting shipped out tomorrow.:w00t:. I'm looking forward to getting them back and getting them on.

[Red Rider]

It's coming together nicely Joey!

[Aulbaugh]

It's coming together nicely Joey!

Thanks Jeff!

[Aulbaugh]

Got some powdered parts back lastnight from Alex @ Gateway PowderCoating.

[ironchop]

I'll bet you're dying to start assembling those crispy new powdered parts. I know I would be.

Looks great

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[Aulbaugh]

I'll bet you're dying to start assembling those crispy new powdered parts. I know I would be.

Looks great


Thanks Doug! Yeah I'm definitely ready!

[Aulbaugh]

Swingarm pictures. Gotta say thanks to a few memebers..... Yaegerb, Red Rider, and Bkm! Awesome guys and glad we crossed paths!

[Aulbaugh]

Sent the rear shock to Selvy for a rebuild/restore and revalve for my weight. I failed to take any pictures of the shock before I sent it off, sure wish I would have.

[Red Rider]

Joey, I assume you know you're missing the bushing and circlip for the rear brake caliper mounting bracket? Otherwise, everything is looking very nice.

[Aulbaugh]

Joey, I assume you know you're missing the bushing and circlip for the rear brake caliper mounting bracket? Otherwise, everything is looking very nice.

Yes sir I have them both on now, I didn't for the picture!

[Aulbaugh]

It's a roller! I went with an RPM Dominator II axle and RPM anti fade brake hub assembly.

[shortline10]

Looking great



It's a roller! I went with an RPM Dominator II axle and RPM anti fade brake hub assembly.

[Red Rider]

Looking very nice!

[ps2fixer]

That harness looks a little different from stock =). Looks like it fits the machine well. Looks like it won't be long and it will be ready to fire up.

[Aulbaugh]

That harness looks a little different from stock =). Looks like it fits the machine well. Looks like it won't be long and it will be ready to fire up.

Another thank you to member ps2fixer for his awesome wiring harness for the 86 250r. It looks great! Thanks again Cory!

[ps2fixer]

Looks like I used looks like too much lol. Not a problem on the harness, glad you like it.

[yaegerb]

That bike looks like it’s ready for an extra special bullet?

[Aulbaugh]

That bike looks like it’s ready for an extra special bullet?

Very close to a VP bullet!

[dvx400]

I'm so glad I found this thread. I'm rebuilding my 85 250r right now. Your way ahead of me but your thread is so informative!!!! Saved me so many head aches and energized me to work on it more. Got my swing arm done the other day using same paint as you.


Thanks again!

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[Aulbaugh]

after seeing ironchop's post on putting the rings in the air box I went the same route. I picked up a couple rings from bdtmotorsports.

[Aulbaugh]

I got a repop front brake line off eBay. I know from onetrackmind's build that the repop do not build good pressure. I learned of HoseFast a hyrualic repair company from onetrackmind a year or so ago when I needed to get a 350x repop front brake line fixed with similar symptoms as his 250r line. I got my 250r repop brake line in yesterday and went to HoseFast today to have an new braided line put in and new banjo eye fittings while keeping the look of the repop.

[Aulbaugh]

picked up some VP C-12 for the engine.

[barnett468]

picked up some VP C-12 for the engine.

Why do you want to run that?

[yaegerb]

Why do you want to run that?

Because I built the engine to run that.

[barnett468]

Because I built the engine to run that.

If he can get away with rm2 109 octane, the engine will make more power with VP MS109 and it is only a few dollars more.

[yaegerb]

If he can get away with rm2 109 octane, the engine will make more power with VP MS109 and it is only a few dollars more.

Thanks for your input.

[Aulbaugh]

A HUGE Thank you to Yaeger Performance Machines for building this motor! It turned out amazing! Here are things that YPM did to it.
1.85 lower end
2.Transmission gears back cut and polished
3.New Pro X Rod std length, crank tins welded, crank balanced
4.Paul Turner Eliminator Cylinder, new LA sleeve with std bore, ported by Duncan Racing.
5.Squish set up to run 110 octane.
6.All new OEM bearings and gaskets
7.Counter Balancer Rebuilt.
8.Cases, Cylinder, and Head powder-coated with a custom ppg darkshot silver.
9.Vforce 3 Reeds.
10.38mm Air Striker
11.O-ringed exhaust flange.

[Fullsizechevy9]

That motor is sexy powder coat looks good

[Aulbaugh]

Got the motor in at Yaegerb's

[Rhino-1]

Looking good!! I'm slowly restoring my '86...

[Aulbaugh]

Looking good!! I'm slowly restoring my '86...

Thanks Rhino-1

[Aulbaugh]

Rads are on

[Aulbaugh]

I picked up a repop OEM rear brake hose from Mike@Vintagemotorsports. The brake line looks amazing!

[big specht]

Hell yea if you are going for a oem build that looks the way to go.

[dvx400]

So Jealous. Bike is coming along great. Cant wait to see the final product.

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[Aulbaugh]

thanks big speccht and dvx400!

[Aulbaugh]

a couple more pictures. Getting close.

[Aulbaugh]

After some thought I decided to get some RPM hubs to complete the rear.

[Aulbaugh]

I know its been a bit since I updated this but been busy with life and I have been battling spark issues on my 250R. Finally gettting the spark issue figured out, I could press forward. Sent my seat to Tammy@Cosmic Quads for a new foam and seat cover. I'm not as big of a fan of the 86 style foam vs the 85 style. So I went with the 85 seat foam with an 86 cover. As always she knocked it outta the park!

[Aulbaugh]

I got the new seat mounted up to the new rear Maier fenders. I picked up the rear black decals from my friend Bruce@BlueLineGraphics.

[Aulbaugh]

I went a different route on the pipe. Went with a custom pipe from Kenny Roberts. Amazing craftsmanship!! Kenny was excited to do this pipe build for me.

[Aulbaugh]

Here are some pictures. A little late getting around to posting them.

[yaegerb]

Here are some pictures. A little late getting around to posting them.

Seriously sweet build bro! Thanks for letting me be apart of it.

[Red Rider]

Now I understand why you never posted many completed pics. You've been out riding the damn thing, and enjoying all the work you put in! Congrats, it came out great. I'm glad the swingarm went to a good home.

[Aulbaugh]

I want to make a post and say thank you to the peeps involved. Thank you for the parts, advice, knowledge, and comradery! We really have a great community of 3 wheeler enthusiasts here that have a ton knowledge and I’m glad to be a part of. I’m looking forward to the next build!!!!!

[jasong_10]

That looks awesome, great job!