81 ATC250r Hybrid Build

[anon3]

Picked this basket case up from a local guy along with the 200x. I don’t have a lot of photos from before hand but it’s fair to say it’s in really poor state.

Engine had a cracked case on the clutch adjuster side.

Came with two back ends. Both had been hacked up and fitted with crappy car disc brake setups.

Had the 200x front end on it as well. https://uploads.tapatalk-cdn.com/20200412/fb91dabcbd987d20647e971cc0540d4a.jpg


Plan for this one is to:

Repair the frame
Fit a Trx450r back end
Stock front end with progressives
Stock motor +1 oversize
DG exhaust
Possibly going to experiment with an electronic shock
New plastics

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[anon3]

Started ripping it apart, engine is in bits at the moment, waiting on my piston to come so I can have the cylinder bored before going out to Vapor blasting.

Ground off all the extra brackets and crap that had been fitted to the frame.

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[anon3]

Found a complete 04 Trx450r back end and mocked it up to give to the fabricator.

I’ll be using the back brake and pedal setup as well.

At the moment the plan is to cut back into the main brace at the engine side to allow the swingarm to clear the back of the engine.

Also relocate the caliper stopper to the other side and fabricate a new chain guard as it’s on the other side.

The bearing carrier will go in backwards which should be fine. Everything switches over easy enough.

If the back cut causes cracking I’ll order a chromoly 450r swingarm from stellar or someone and ask them to clearance for the engine.

Few photos show the issue.

Also need to weld in a new frame cross brace below and behind the current one to allow the linkage to attach.

Last just need to machine the bushes to fit with the old swingarm to engine bracket.

Shock will sit a bit further forward on the frame to make the geometry work out.

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[sledcrazyinCT]

Good start on your hybrid:beer

[anon3]

Decided to go straight to the custom mild arch swinger from Stellar, reasoning being that if I made the mods to the frame for a custom TRX450R swinger I’d be stuck with having to cut and weld each time I need to replace.

Ordered some bits, and sending the engine out for Vapor blasting this week.

Found a 300r kit on ebay, which is now over at CT racing getting things sorted before heading my way. Needs a sleeve and a re-dome plus piston.

Picked up a durablue 2+2 for the backend for $200 on ebay, and a LSR billet carrier for $80.

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Sent from my iPad using Tapatalk Pro

[anon3]

Built my own Vapor blaster in the end. And settled on a colour. Building now.

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[anon3]

Build list:

Stella swingarm, 450r with sides reversed (if he has time)
Dura blue rear axle, 450r carrier and brakes
Original front shocks
Hill climber rear
Standard bottom end with 300 kit
Clake two lever
Brake pedal delete
Keihin carb upgrade

Paint and panel, though mainly paint. Keeping it fairly raw.

[wild200x]

looks good. following.

[anon3]

Thanks, bit more progress today. Paint is duplicolor metalcast anodizing spray. It’s a real pain in the ass to apply, has to go on really thin.

Worked out a process that works for me in case anyone else is suffering through using it.

Blast parts back to metal
Heat part to 75C
Apply 2 light base primer coats followed by two wet, 5 mins in between
Back to 75C
Apply 4-5 light colour coats 5 mins apart
Back to 75
Apply 4-5 more colour coats 5 mins apart
Bake at 105C for 24 hours

Colour changes with more application so consistency is key. I like the finish, and I’m going to use it on the frame as well. For that I’ll blast it, light base coat so I can still see the frame patina, and then relatively light coats of colour. Should be able to see the patina through the coating.

My shock has D/G stamped on it, were they made by DG?

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[jasong_10]

That red is awesome

[patriot1]

I am ready to see this finished. Very interesting build

[anon3]

Bit more done. https://uploads.tapatalk-cdn.com/20210313/26186a113341603af887f3297792548c.jpg
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[anon3]

How do you get this drum stopper on? Any tips? Spring is a pain.
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[dieseldigger]

That bottom roller is a pain in the ass. Just keep fighting it carefully. You'll win. I usually use a flat head screwdriver and a pick set. No to mention a lot of choice vocabulary. Just make sure the spring is sitting properly on the bottom collar or when you put the top roller on, it won't fit properly on the post. Honda used this roller detent system on a lot of their earlier 2 strokes.

[anon3]

After many a choice word I managed to get it on. Then realised I’d missed a washer in the trans. Easier the second time around.

Just waiting on my spec bolt kit now.

Frame is next, just need to finish up the welding and get it painted up.

[anon3]

Frame done, front end should be on in the next couple of days. Just sorting out bearings for the stem.

I weigh 200lbs, what’s the thoughts on fork oil weight? I’m going standard front end with progressive springs.

Fork tubes straightened today. https://uploads.tapatalk-cdn.com/20210324/7253fc2deb35bf6926ab690154ef9417.jpg
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[patriot1]

Awesome build.

[anon3]

Bit more done, waiting on parts again now.

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[anon3]

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[jasong_10]

Still looking good!

[anon3]

Still slow going here. Got my engine top end all assembled and realised the piston is the wrong size, new one on its way from the supplier. They must have picked up the wrong one off the shelf as they did the bore.

Found a shift spindle and shifter, waiting on that.

Got the front assembled and the hub has been cut down 50mm on the disc side! Love previous owners. One on its way now.

Stella are making the swingarm now, so hopefully by the end of may it’ll be close to done.

Trx450r axle and parts all coming together.

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[dieseldigger]

Looks like you're going with a hydraulic clutch? Is it a Magura? Which slave cylinder model are you using?

[anon3]

Looks like you're going with a hydraulic clutch? Is it a Magura? Which slave cylinder model are you using?

Hey mate, I’m using a Clake Two lever on this one. It’s a combined clutch and rear brake lever. When you engage the rear brake the clutch gets pulled in as well, how much, or if at all depends which cams you fit in the lever. Had it laying around, should make wheelies fun.

It’s using a Magura hydraulic piston and it’s directly driven off the lever master.

https://www.clake.com.au/clake-two-dual-standard-control/

[anon3]

Swingarm just finished up Fab, new piston finally on the way from CT and found a good shifter rod. Should be back to building soon.

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[jasong_10]

Wow, those look amazing!

[anon3]

Engine set except my shift rod which is on the way. Should be in the frame soon.
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[jasong_10]

That looks awesome!

[MrConcdid]

Impressive, Thanks for sharing.

[anon3]

Bit more progress today, received my shift rod and managed to close up the motor and get it fitted to the frame.

Magura slave looks to fit perfectly.

Electrics tidied and refitted. Front end should be on tonight all going well.

Swingarm finally left the states today. Just need to order an intake boot for the air striker and it should be running fairly soon.

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[dieseldigger]

Which magura slave did you use? Part number? Retracted and extended length?

[coolpool]

That is going to look like one slick machine! Keep posting......

[anon3]

Magura slave is a 0120653.

Few more pics of mocking up the mirrored 450R stella swingarm, fabricating a bracket for the linkage to run off the rear engine bracket.

CNC fork to convert the hill shooter from eye to fork. Intake on the way, along with front wheel spacers and plastics, think I’m done ordering parts now.

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[anon3]

Here’s the fabricated bracket for the lower linkage. I was going to CNC it but the cost came back way too high. Anyway, this allows me to fine tune the placement with the slotted mounting hole so I can play with the right amount of angle.

With this, and the shock foot it should work pretty well.

Not sure on the swingarm shade yet, might go less flat.

Axle end of the linkage is on it’s way, lowering link so I can set the geometry.

Next is getting the swingarm into the right location, need to surface grind the outer faces 4-6mm on the left, 2mm on the right for clearance and to line up the offset front sprocket.

After that it’s making up the spacers for between the swingarm and engine mount.


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[anon3]

Little bit more done. Mainly the pipe.
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[anon3]

And a bit more, waiting on a few parts to come in this week and hopefully it’ll be on the ground at the end of it.

Intake fitted thanks to Valley Motorsports, 38mm air Stryker and uni filter.

Fitted the swingarm to get spacers sized up and locked up the linkage. Think it’ll work. Might need to for a shorter axle side linkage.


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[anon3]

On the ground and fired up for the first heat cycle. https://uploads.tapatalk-cdn.com/20210724/8e805cc58220260ff55900c65cc68a6f.jpg

[anon3]

Update. Waiting for plastics, Brembo rear caliper and sprocket guards - seat being done right now.

After that decals. https://uploads.tapatalk-cdn.com/20210813/3ac833d0a1613feea490edf7930d00b8.jpg
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[patriot1]

That paint looks awesome. I wish I had the skills.

[jasong_10]

That paint looks awesome. I wish I had the skills.

Same . . . great job

[anon3]

That paint looks awesome. I wish I had the skills.

Rattle can - just have to make sure you get everything clean. It’s really easy if it’s prepped well.

[anon3]

And finished this one finally too, runs really well, a lot of fun to ride.

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[Red Rider]

It came out very nice! I like the finished product. Now go enjoy it!

[jasong_10]

Still can't get over how nice that red is, great work.