Shaun's (AR's) CRM250AR/CR250 Conversion

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knackeredMk1
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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by knackeredMk1 » 20 Jun 2012, 09:28

All the bits I had been collecting were ready for the engine rebuild:

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Barrel cleaned:

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In the mean time I took the suspension off to be re-valved and softened to suit my weight and riding style:

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Now, unfortunately the crank had spots of rust, and I immediately feared the worst!! Hence I had saved a lot of money to prepare for the worst case scenario, which was confirmed when the crank was split. Although no play in con-rod, rust marks are a no-no, therefore I decided to have it rebuilt.

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New conrod kit supplied by Leisure Trail (I think off a Maico 490 or something):

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Here I attempted to clean up casting defects and improve the gas flow in the cases and barrel (please don’t copy this or slate it as I don’t profess to be Stan Stevens):

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I later read that this ‘mirror’ finish is incorrect, and it should be not so smooth, so roughed it a little using a coarse scotchbrite:

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I also trimmed the base gasket over-hang, again to improve gas flow:

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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by knackeredMk1 » 20 Jun 2012, 14:55

I also gave the power valve a dam good clean. Before:

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After:

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I finally sourced some similar new engine casing bolts, took me ages to find, and had any odd sizes and bits zinc plated:

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Crank cleaned and rebuilt by SEP:

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I think the final, and very most exciting parcel arrived in the post:

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My sexy new wheels, wow was I pleased with them, but gutted they went up £100 just before I was ready to order:

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Also some carbon fibre bits I ordered:

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I cleaned the frame as best I could, but decided not to polish it as it’s an offroader:

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And so here begins the final build (whilst awaiting the engine from Leisure Trail) – Boy was I getting excited, and impatient waiting for the engine to return.

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Ready for engine ;)

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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by knackeredMk1 » 20 Jun 2012, 15:01

Renthal flexi-lever (I ended up buying both clutch and brake levers):

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Hydraulic brake switches and brakes bled:

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Finally had the rear sprocket spacer finished on the machine (it had to be tweeked to suit the Talon hubs, and lightened by removing excess material):

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Wheels with tyres and mousses, sprockets and discs fitted:

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Yessss….. engine back, and looking fantastic!!

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Freshly plated bore:

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And in she goes…..

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Custom exhaust flange with brand new gasket:

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Swing arm in:

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Coil on and starting to pipe up rads:

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Further progress:

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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by knackeredMk1 » 20 Jun 2012, 15:08

Boyesen Reeds (I did try the RAD valve for the CRM, ordered from America, but it wouldn’t fit upon final build- LONG STORY!!):

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Cables, wiring and hosing under tank:

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Vaccuum hoses into airbox:

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Getting there slowly:

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Shiny head steadies bolted in place:

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Oil tank ready with solenoid mounted:

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Further progress:

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Fuel in, and now she’s ready to start, I was so nervous, I was literally shaking:

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OK, to be honest took ages to start and I couldn’t figure out why, good spark etc and fuel getting through. Finally started but wouldn’t tick over. Later I found out I had the tickover screw the wrong way, as it works the opposite way on the AR to what I’m used to. So I had her running, now had to get the plastics chucked on and ready for the MOT, which was booked in about an hours time. The final build from the bare chassis only took one or maybe two full days.

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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by knackeredMk1 » 20 Jun 2012, 15:16

And off she goes for the MOT, which she flew through bar the advisory for no rear chain guard I think:

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Once MOT’d I had to register her at the local DVLA. I had checked all this out beforehand, and got all the necessary forms and paperwork. All seemed to go well, until I got a letter through saying that my ‘Year of Manufacture’ certificate from Honda was wrong (they had put an extra digit in the chassis number). I ordered this well in advance as I know they take a while to come, so I had to pester Honda for a new one, and to hurry up with it. Eventually the new one came, and I went back to the DVLA and registered it. It was now a waiting game for the log book through the post and so I could insure it on the road. Finally this came, and I took her for her first blast on the road!!

Here’s just some of my favourite finished pictures, I hope you like them, apologies for so many:

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Thanks to my sister for the above coloursplash photoshop edit which I begged her for, she had this printed on a canvas for my birthday.
Unfortunately the bike doesn’t look this good now, which is why I took so many scenic photos when I first built her. She has the obvious usual signs of off-road use, but this is why I built her after all. I must say she’s a pleasure to ride, and really puts a big grin on my face every time.

I have experienced several teething problems as expected, all of which I have now sorted. I did re-jet the carb once after a plug chop and a play around, and since have had the bike dyno’d. Max power was 30BHP with 22lbf torque. To be honest I expected a little more, however after reading on the forum, it seems that is about right!! I still haven’t weighed her, but not too fussed. I’d like a comparison to modern Enduro bikes, however I’d not be too competitive, as I haven’t aimed for maximum lightness, mainly practicality and looks.

The project took around a year from start to finish, during which I was at work full time, at Uni part time and bought my first house, so not too bad considering!! It cost in the region of £6,500 to complete, but the cost was nicely spread by buying bits as and when I could afford them. It meant many sacrifices had to be made, but was worth it! It could have been done an awful lot cheaper, but could have also cost a lot more. I don’t regret any of the money I’ve spent on it, as it’s now exactly as I want it!! Just one wheel is worth more than my entire car!! Haha.

Here’s a few pics out and about (apologies for the ones taken on my phone):

Here she is, line up against my mate’s AR, a nice comparison:

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And lastly a few action shots of me pratting around on her, not long after a steady running in:

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Finally, I must say a massive thanks to the following people, who have helped me in one way or another towards this project, without you all, I’d probably be sticking a box of bits on eBay.
Therefore, a big thanks to:

• Firstly, everyone who has helped me financially, by either lending or giving me money towards it, or buying Christmas/Birthday presents which are now all over the bike.
• Everyone at work that has helped (far too many to mention) for all your time and efforts.
• All the lads on this Forum for continued support and advice (even though I managed to keep the actual project a surprise).
• Shock-Tech suspension for the suspension re-valve and set up.
• Pro-Racing for all the excellent quality aftermarket electrical items.
• Gary at Fusion graphics for the fantastic custom graphics kit, thanks for your patience!!
• Both my neighbours for receiving parcels all the time when I’m at work!!
• Leisure Trail for sourcing CRM parts, and the full engine rebuild.
• The lads at CJ Ward for all the Powder Coating.
• MX-Bits.com for all the pro-carbon accessories and those lovely wheels!!
• A special thanks to Scott Clarke and Glenn Williams (Glenn who owns a CRM mk2, and is on here as ‘250greenlane’), two very good friends of mine who have helped in many with their knowledge and experience, and kept the banter rolling. Massive thanks lads, I owe you both a beer or three!!

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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by njhardy » 22 Jun 2012, 08:08

A stunning project Shaun- I bet you are well proud. Well done. What's next?

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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by Active Rascal » 25 Jun 2012, 11:25

Thanks very much Steve for posting that up, and thanks nj for the comment. No plans next, I was going to do my old AR up as a super, super-moto, but I can't justify spending the money!! :(

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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by back off road » 26 Jun 2012, 00:10

cant justify spending the money ???? how do you justify £6.5k on a trail bike project ?
Im thinking about a bike with more valves than a powervalve

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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by knackeredMk1 » 27 Jun 2012, 09:56

BOR - Won't even bother answering that :roll: .

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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by Active Rascal » 27 Jun 2012, 17:06

Yes I can justify it, to be honest this is probably my one and only bike project (at least for a very long time) so I might as well do it right, have it exactly as I want it and have no regrets. Hopefully it will last me a long time. Trail riding and Enduro is my hobby and passion, and I try to use the bike at least once a week. A super-moto to me is a 'nice to have' and would hardly ever get used - Hence I couldn't justify spending a small fortune on it, when as I said, one wheel off the CR/M is worth more than my car!! :)

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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by twistednuts » 27 Jun 2012, 23:42

That is fantastic. Worth every penny i reckon. No need to justify it really, but i'll do it for you.

A new bike would cost a bit less, but you got a virtually new bike totally tailored to you, an most likely had a great time building it, its win win win.

You could of peed the cash up against a pub toilet wall, which you probably did some of the time :D

The only downside is, how can you bear to get it dirty? :shock:

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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by HotWired » 01 Jul 2012, 08:40

Thats an awesome build! Love it! And you made it look do easy.

Ive been looking to sell my CRM-AR for a new CR250 as I want something thats lighter and handles better (plus they look good). Only thing that has been stopping me is recreational licence arent that great here in Australia and I like having a road rego'd 2 stroke. Maybe this is the answer :-)

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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by BaNZ » 23 Jul 2012, 05:59

Brilliant! It was a LOT of hard and interesting work, but it definitely worth it.

Personally (if someone cares) I don't like aluminium frames or modern CR/WR bikes neither. Also I cannot really understand how lightweighted enduro bike such CRM with sharp handling can be more light and sharper. But overall suspension and chassis of modern CR way better then CRM's.

Excellent job and nice looking conversion!

P.S. I believe that's how should look modern 2t Honda's enduro, if they would ever produce it.

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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by jompy » 23 Jul 2012, 19:32

WoW !
Looks stunning , a great write up & lots of pic's :)
you ever thought of giving TBM a call they may do an artical on it

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Re: Shaun's (AR's) CRM250AR/CR250 Conversion

Post by Active Rascal » 23 Jul 2012, 21:54

Cheers fellas!! Yeah I emailed TBM, they said they were very interested and wanted to give it a full test ride, then never got back to me!! It was in the TRF monthly mag a while ago, and I sent it to TMX News weekly, but didn't get a reply, and don't know if it ever got in!!


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