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Old 02-08-2010, 04:28 PM   #121
DisTech OP
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Quote:
Originally Posted by RandyM
I have a project to fix up a DR250s, so I'm keeping and eye on this thread for ideas.

Reguarding transmission gear swap, I have not done it. However it looks like the DR250S has a wider range than the other models.

Here are the transmission gear ratios according to the Clymer manual (1990-94 models)
...
Thanks RandyM, I hope to see your DR250S upgrades thread!

Excellent info and it looks like Jesse was on the money with the DR250S 5th being the same as the DR350 6th.

5th 19/23 (0.826) 20/21 (0.962)
6th 17/24 (0.708) 19/23 (0.826)

You also cleared something else up. I was looking at the DR250, not the DR250S. So I went back to the online fiche.
  1. Ronnies Mailorder has complete descriptions and they have both sizes of 5th and both sizes of 6th gear (although it does say "call for pricing" on the gears I want).
  2. MR Cycles has complete descriptions and they have both sizes of 6th gear but only the common size for 5th.
  3. Ron Ayers parts descriptions are chopped off so short you can't even tell what the part is.
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Old 02-08-2010, 05:00 PM   #122
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The DR250S 6th gear combo can be purchased from Bike Bandit ($134). 3rd and 4th seem to be discontinued.
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Old 03-08-2010, 12:50 PM   #123
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Where's the action? I'm stuck in a shit town down in Patagonia waiting for a rear shock. What's new with the DR??
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Old 03-08-2010, 06:35 PM   #124
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Hey Spencer, glad you weren't affected by the quake. I had a bunch of your RR pictures running as a screen saver on a 30" Dell monitor I've been demoing at work. Incredible shots!

I've been accumulating parts mainly, not to exciting. One shipment from Jesse came in, but I'm still waiting on the head, piston and jug for the 455. But you're right I've been slacking on the thread a bit. So here we go, thanks for the kick in the ass!

I got the frames back from Seattle Powder Coating a week ago. Still wrapped for my protection.


Re-assembled 93 crank with new connecting rod and bearings. I sent it to Jesse dis-assembled and he chewed my ass a little until I told him that how I got it. Apparently it's a bitch to true it back up if you don't mark how it's aligned beforehand. 94 crank now has the counter weight gear pin plugged so it wont work it's way through and explode my engine. The 6mm shift cam stopper bolts have been upgraded to 8mm. And a Keintech oversized stainless header!


DR350 stem pressed into KTM 4860 triple at the bottom, new bearings and a machined sleeve for the KTM triple at the top. Same thing Ron Seida did for his DR650 build. Jesse does nice work.


The 94 5th drive and 6th drive gears have minor spalling just where shown in the picture (if you can see it). 5th and 6th driven gears don't have this. I've been trying to order the taller 5th and 6th gears from the DR250S for a few weeks and every time I think I've found a dealer that has them in stock, they enevatably tell me they are discontinued. All the 93 gears look fine, I think that motor has seen fewer miles even though it's the one the the connecting rod broke on.


New Megacycle cam with welded and ground tappets for the 455.


Keihin FCR-MX37 (TPS, hot start, ACV) from a 01 WR250F.


I've been researching lighting and controls and right now the plan is this.
The 455 is going to get BajaDesigns 8" racelight with the 35watt HID upgrade just like Spencer did. The 350 is getting a TrailTech X2 (thanks WB-PDX). The 455 and maybe the 350 will get some Highway Dirt Bikes controls, they make sweet compact stuff.
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Old 03-08-2010, 06:37 PM   #125
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Oo oo oo! I just paid too much for this on ebay! 93 DR250S motor. That's another S model stator that I need and it's the correct year 250S that has the higher 4th, 5th and 6th gears! And one of my 350's will have kick start and the magic button!
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Old 03-08-2010, 10:03 PM   #126
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Quote:
Originally Posted by DisTech
Keihin FCR-MX37 (TPS, hot start, ACV) from a 01 WR250F.
What's ACV stand for?

Nice score on the engine BTW.
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Old 03-09-2010, 09:51 AM   #127
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I feel famous, I got a mention in this thread!
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Old 03-09-2010, 10:13 AM   #128
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Quote:
Originally Posted by DisTech
Oo oo oo! I just paid too much for this on ebay! 93 DR250S motor. That's another S model stator that I need and it's the correct year 250S that has the higher 4th, 5th and 6th gears! And one of my 350's will have kick start and the magic button!
I was thinking about bidding on that, but decided to wait until I get my DR250s converted back to California street legal before spending any more money on it. Are you going to install the crank and cyclinders in that engine and convert one bike to electric start? That would be a nice touch on the project.
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Old 03-09-2010, 03:02 PM   #129
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What's the diameter of that header?

Quote:
Originally Posted by DisTech
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Old 03-09-2010, 04:22 PM   #130
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Quote:
Originally Posted by pablo83
What's ACV stand for?
Air Cut Valve. On decel it cuts the air, thereby enriching the mixture and reducing decel popping out the exhaust. Same deal as mx-rob's FCR-MX39 for the DR650.

Quote:
Originally Posted by pablo83
Nice score on the engine BTW.
Thanks, I hope the transmission isn't wasted.

Quote:
Originally Posted by WB-PDX
I feel famous, I got a mention in this thread!
Ha! Yea I wish I had something useful to contribute to your 1990 DR 350 S Pimpification thread.

Quote:
Originally Posted by RandyM
...Are you going to install the crank and cyclinders in that engine and convert one bike to electric start? That would be a nice touch on the project.
I'm going to steal the stator and the taller 5th and 6th gears for my 455 and make the 350 have electric and kick start.

Quote:
Originally Posted by yondering
What's the diameter of that header?
1.5" OD as apposed to the stock 1.375" OD.
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Old 03-12-2010, 02:14 PM   #131
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Turbo Charged?

Have you considered creating a Turbo DR450?

100 horspower is possible.

(yes, I am serious.)
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Old 03-16-2010, 07:40 PM   #132
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The 93 DR250S motor showed up today! The UPS guy was glad to be done with that 88lb box.

I'm pretty eager to see what it look like inside, so I started tearing it down.


Aside from the grime everything inside looks really good so far. The ebay seller said it shifted through all the gears but had low compression. Looking at the head I don't see why it would have low compression (I'll put up some better pictures). One thing I though interesting is there is no manual or automatic compression release. Maybe 250 is small enough you don't need it?
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Old 03-17-2010, 02:05 PM   #133
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I read through your 650 build again for old times sake. Nicely done on both projects.

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Old 03-17-2010, 07:47 PM   #134
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Thanks Whitey!
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Old 03-17-2010, 08:17 PM   #135
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Got a bit farther tonight. Stopped by the 27mm nut holding the primary drive gear. Didn't have any problem getting that thing off on the 350 but this one is tight! Buy the proper tools tomorrow.

Been comparing the 250 and 350 cases every step and so far they appear identical.




The ebay seller said low compression but the head looks normal and the cylinder looks better than it should. Doesn't make sense to me.


The 250 barrel is smaller diameter and shorter but the bolt patterns are identical to the 350.




These are the 93 250 and the 93 350 heads. Everything (including the valves) appears to be the same size, except for the intake. The 350 intake is 33mm and the 250 intake is 30mm. Why'd they do that?


Hope to split the case tomorrow and see if 5th & 6th gears are the ones I'm looking for.
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