My WR250R Build.

Hi all,

Here is where I am going to document all the modifications etc that will be done to my newly purchased WR250R. It may be interesteing to some, it may not be to others, you decide whether you stay and read on.

So first off, I bought a bone stock 2010 black WR250R. It only had 3700km on it and was only 6 months old, so still still has a year and a half of its warrant!

The first thing I did was fitted a wolfman enduro tank bag.

Next was fitting a Zumo 550 and a 12v outlet to power it.

Making up the mounting bracket and doing the wiring with fuse:




Getting into the guts to find some wiring:






Mounting of the GPS:






Final mounting point for the 12V oulet:

Next was removing the seat strap because it was annoying. Removed the bolts, strap came off, glued the foam back down:

I then started knocking up some pannier racks to suit my old RJays bags. This will only be a temporary thing until I get my giant loop.

Back frame:




Measuring and mounting of back frame on the right side. Using the pillion pegs for the front mounting point:




Using the hole above the exhaust mount for the top mounting point:






For the rear mounting point I used the stock number plate section:







Right side complete:





Left side front mounting:




Left side top mounting using the helmet lock section:




Both of the rear mounts in and done:




Left side now complete also:




From the rear:




Bags just thrown over:




Clean and undercoat:




Completed ready for fitting:




On the bike:

I fitted a waterproof 12v outlet under the seat with fuse etc. This is used for a pump, charging phone etc so you don't need the ignition on like the 12v outlet at the front of the bike:

Sanded out the scratches etc from the exhaust cover and painted it flat black. Not sure if I like it or not yet, might go silver:

Before:





After:

Went on a decent ride with the bike fully loaded, full ride report coming soon:

nice work on your bike .. that last picture, it looks like everything is solid, nicely distributed .. just curious, will your back tire clear that cross bar support on your rack?

never mind the question about the crossbar, I just looked closer in one of the pictures and see how you did it .. for some reason I thought it was straight across

What kind of license place bracket is that?

Nice job
Do you have to run the polution crap over there?
There's a bunch of room to be had under the seat with all the gear pulled out

Crypto: Like you saw mate, yeah, they don't go straight across. They tyre will never hit.

WRXR: That is the standard issue Australian one.

0007onWR: Keeping the bike pretty well stock while it is still under warranty mate.

BTW, the muffler shield looks great in black.

impressive job on the racks, i like the giant loop also but i wouldn't pay 400 after that effort, looks great too

Here is my first ride report for the WRR.

https://wr250rforum.forumotion.com/t4243-three-dayer-on-my-new-wr250r

Found a better spot for my rego label:

Today I whipped up a quick bash plate. Just out of some old thin aluminium I had left over. I will be making a rallye style bash plate for it with the tool boxes either side when I get some thicker aluminium.


Cutting a template out of cardboard:




Shape cut:




Starting to bend up:




The dodgy weld (gasless mig welding......




Holes drilled and on the bike:








I made it high to protect the radiator guard:




This side needs to be bent in a little more. I also have to drill the oil drain plug hole and I may also do some holes in the front of it to let some airflow with some mesh behind it.

Bought some bar end mirrors. Took them apart so they could mount to the bars:




Fitted up with old mirrors on to see the difference:




Both on and cleaned the front of the bike right up:

Very nice,I like that your plate covers that exposed radiator hose. The mirrors look good too, I have got to do something with the stockers on mine. Where did you get those bar end mirrors?

Yeah, I purposefully made the bash plate go up that high to cover the radiator hose. The mirrors were just from e-bay something like these:

http://cgi.ebay.com.au/Pair-Motorcycle-Bar-End-Mirror-Honda-Yamaha-KTM-BMW-/180652769803?pt=AU_Motorcycle_Parts_Accessories&hash=item2a0fbe820b

MotoKirby wrote:

Very nice,I like that your plate covers that exposed radiator hose. The mirrors look good too, I have got to do something with the stockers on mine. Where did you get those bar end mirrors?

That's the bash plate that everybody else should have built. HighFive was a casualty of insufficient bash plate coverage, somebody else reported a smashed pump cover the other day, and there's probably a few others out there as well by now.

Clean the lines and design up a little bit to spiff up the visual appearance, add the holes you mention, and you could easily end up being Sandman Parts v2.0, selling your good ideas to other members of the zoo... I'm probably low risk for damage caused by insufficient bash plate protection - but I think about it a lot when I'm up in the Rockies 70 miles from nowhere and zero vehicle traffic on the roads. I'd buy one...

BTW, for you and others with the underbar mirrors, can you actually get good visibility of traffic behind you with those things, or do they mostly just keep you legal. The stock mirrors are no screaming hell for visibility directly behind as it is without doing a little elbow tuck, so if underbar mirrors were the same or better, that would work for me.

Today I fixed up the bash plate a bit. I folded in the left hand side more cause it was sticking out too far. I also drilled a hole for the oil drain plug. I don't like the hole though and am going to weld it over. It is only four bolts to take the bashplate on and off and I know that the hole is going to be the first place a rock or something goes and holes the engine case:

Did an oil change. I ended up going with the proper Yamalube for the first change cause it comes with all the Orings and washers needed as well as the oil and filter.

Did you notice the oil change kit from Yamaha, originally intended for the 4-stroke YZs from 2003-onwards, doesn't have a drain plug washer in the 12mm size needed for the WR-250R/X?
Same story here in the USA.
It is a handy kit, though. :)