My WR250R Build.

I was reading your build thread and your bike looks awsome!! thanks for all the pics. I was wondering, in the picture of your tool caddy, I see 3 CO2 cartridges and was wondering what they were for? Cheers, Kirk

They are for tyre inflation, they are inserted into my pump for quick inflation after a flat.

Took the bike out to a motocross park the other weekend, what a blast!! I have never really jumped a bike much before and damn it was fun!! My suspension has been fully reworked with heavy springs etc, but the front end bottomed out a fair bit over the day. I will definitely be doing it again.

Indicator broke after some hard riding, so replaced it with a new one:





On that note, I also never got around to doing the head light guard and a mate's roost cracked my headlight too!!


Anyway, got myself an air hawk for some of those longer trips:



Bought a staintune exhaust:



Stock V Stainy



Fitted the stainy up, O2 sensor in, found an awesome hose clamp and also a tiny bit of gasket goo, just to make sure it sealed properly:




Hmmmm........ well that doesn't work out too good does it!!



While I did the exhaust, I did the flapper, removed all the AIS, the EXUP stuff and all lines etc:



Fair bit of junk gone!



Found a great bung for the airbox side of the AIS:



Made up a plate for the AIS entry:






I also modified my front tank bolts because it was rather difficult to locate them when putting the tank back on:



Did a quick solution to the exhaust positioning problem:



My friend Charlie was overlooking my work:



Closer look, just a carpet python:





Here is the resistor I used, because I had already run the bike without the EXUP plugged in, it had thrown the code and had the light on so I had to plug the EXUP back in, then disconnect and put the resistor in place, No more light!!



Also gave the air filter a clean because I wanted everything to be tip top for my first ride with all the mods:



I also got some white side covers and white fork guards, the beginning to the bike being totally changed to white when I do the fairing:







So here is a quick clip of the new exhaust:

So today was supposed to be a "Family Day" but my daughter has pneumonia (not bad) so instead of heading out, we just pottered in the shed. The job took much much longer than it normally would, but it was way more rewarding!!








So anyway, I have a ride coming up next weekend and with the new exhaust, I needed some sort of guard to keep the Giant Loop off the exhaust. I didn't want to spend long on it, so just whipped it up real quick.

It is a simple plate at the top that is riveted to the aluminium guard that I had made earlier for the stock exhaust. Small diameter round bar laddered down to another plate which bolts onto one of the pillion peg bolts:













It leaves plenty of room for air flow so the bag doesn't get hot from the exhaust. I will be making a better version at a later date.

Well a fun read this morning. Your having a good time with it. Could have fooled me on page one when you said" Keeping the bike pretty well stock while it is still under warranty mate." Look forward to the next shop adventure! How's your airhawk working out. You like it? I have the Seat Concepts and like it much more than stock but also needed more. I put a long haired sheep skin on it, which works great for me. Kind of like sitting on your dog.

mordicai wrote:

Well a fun read this morning. Your having a good time with it. Could have fooled me on page one when you said" Keeping the bike pretty well stock while it is still under warranty mate." Look forward to the next shop adventure! How's your airhawk working out. You like it? I have the Seat Concepts and like it much more than stock but also needed more. I put a long haired sheep skin on it, which works great for me. Kind of like sitting on your dog.

Yeah mate, loving the bike. It is too damn hard to keep anything stock!! I always modify my cars and bikes. Next workshop adventure will be mounting my UHF and placement of Push To Talk button. Then keeping going on my bash plate.

I haven't actually ridden with the air hawk on this bike. I have had one before when I had a DR650 and Vstrom. I LOVED it then, so I am sure this will be the same on those longer rides.

Uhf ? 70 cm? You a HAM ? Been thinking about mounting a 2 meter rig on this bike. KJ6UWP

It is just one of the small 5W hand held units. I am setting it up with a throat mic and a push to talk button on the handlebars.

One of thse guys: http://www.uniden.com.au/australia/p_uh078SXnb_index.asp

WOW! That one looks pretty fancy with heaps of features! My mate and I just got units that were waterproof and durable just to have some good quality, resonably long range bike to bike coms.

Ok, so here are a few things that have been happening over the last few months.

New wheel bearings for the rear:


Bit of heat for the hub and cold (freezer) for the bearings:



Slipped right in!



Quick little UHF mount I made up:



Mounted (just to the right of the GPS):



I added some heat tape to the back of the Giant Loop to try to cool things down inside the bags a bit:



Lost the bottom bolt from my kick stand, so replaced that and added a bunch of loctite to both:







WOOOOHOOOOO!!!! Finally a full exhaust!!!



Outing with the old:









So anyway, I am in Australia and we have the bikes with the Oxygen Sensor plumbed into the stock exhaust. So I had to get one plumbed into the new exhaust. Something I would normally do myself, but seeing as it was stainless, I wanted it done all in stainless. Turns out no one had the stainless bungs anyway! So got a mild steel one welded in. I marked it all out and got a local exhaust guy to do it:




BUT........ he did it in the wrong spot slightly and definitely not on the angle I told him it had to be in!!! So I ended up having to cut the bung out and re-weld it myself anyway!! The highway-robber charged me $40 too, for something I should have just done myself so it would be right!! I added a quick lick of paint which burns off anyway:



all in position:



All done, in and running!

So I sold the sports cars and got a van! How embarrasing! But it carrys the bike nicely.





Loading two bikes is a bit harder by yourself I found out!!



Anyway, it was finally time for some real maintenance. Chain, sprockets and chain slider.......and swing arm inspection.........











Thankfully it had only just started touching the weld on the swingarm, so no actual damage was done. I was running a 12 tooth front sprocket for a long time with a really dodgy chain which had many kincked links, so it was inevitable.

Old slider:



Old V New:



New front sprocket:



New rear sprocket:



new chain and all back together:





I added some big hose clamps to help support the tool tube and they could come in handy for fixing something on the trail one day too!



New underbar mirrors with convex glass:





I revised my number plate lighting too with number plate LED bolt lights. Also new rear indicators:







I did an oil change too on it but the damn O-rings leaked on the oil filter cover, so had to get some new ones and lay the bike over and change them over:





You can also see in this one the bit of bling I added with some gold rim tape front and rear:



So that is it for now. I have some new levers to fit, a new front braided brake line. I have to finish the bash plate with tool boxes and also fit up the fairing setup which i am collecting all the parts to start it.

Nice work.

I had an FMF PC4 on my bike and it was way too loud for my tastes. Good luck with that.

How many miles/km's were on that chain slider?

Looks like you really caught it just in time.

How many teeth on the new rear sprocket? Looks sexy.

Coop: Yeah the thing is pretty damn loud!! But it gives me the best performance, so that is what I was looking for.

Motokid: The bike has 13000km so it hasn't done too bad considering the chain condition and running a 12T front sprocket for so long. I knew it was bound to happen and checked it regularly for a period after fitting the 12T front, but got lazy after a while and forgot about it. So yeah, caught it just in time for sure.

I am now running 13/47 with a DID 520VT2 chain.

47une wrote:

G'day mate. Yeah, it's my property, about 45 acres worth. I have just finished making the track and I ride the track every single day. I feel a bit strange if I have to miss a day of riding it....

You are quite the lucky man to have a setup like that in your own backyard!

Good call on the height of your skid plate. I had a branch knock out the solid tube between the flex hoses on my WR - got it fixed with no issue and the tube wasn't even dented.....kind of makes me wonder if one of the clamps was missing from the stealership.......

Looks great in black!

Is there a place to order Yamaha parts online from OZ?

you can email me... happy to post stuff

where was that motor cross park you went too?

Been a long time since I have updated here, so here goes with all the stuff over the last few months:

Started the big changes with going all white plastics:



KTM front guard:





Some gold rim tape for a bit of bling:



Some new folding levers, much shorter, really quite good:





Lack of adjustment on the brake master cyclinder though:



New front guard fitted:





New levers:





Low guard.........nah:





Setup of the new tail with foam tape where factory put it:



All new white plastics (Except headlight, not needed for future fairing)












So then continued on with my rally bash plate making:









Fitted a rear rim lock as, due to lack of care and attention, let the rear go so flat I ripped the valve stem!!



Took a bit of balancing!!





Heading off for an overnighter:



New front braided brake line and new brake fluid front and rear:







Bash plate all welded up (THANKS DRJOE!!!!!!) My welder is not set up for alloy unfortunately!





Making the lids:







Fitted:









Beginning to sand and polish everything:



Latches for bash plate mounting:



Cleaning down all welds:



Inside:



Sealed with silicone just in case:





My buffing setup, cheap, but very very effective!!















ITS A MONSTER!!!!!













Nope, that is going to rattle around WAY too much!!



Winner:



Now onto the bloody pesty leaking fork seals!!















This was such and easy and enjoyable job, I would NEVER pay anyone to do it ever!!

So it was now time to get onto the serious job of doing a full fairing and nav tower, not a minor job to undertake by any means!

Sourced some decent headlights:



Fit like a bloody charm! Also some indicators fitted too:



Cad drawings........computer modelling......CNC machines..... Nope!!! Some old steel, set square, tape measure and pencil and paper mate!! It's the Aussie way!!



Head gear all removed:



Removing the ignition barrel:









Now for Nav tower mounting:





Yup, real mans stuff!!












The scariest part of the whole job!!! PLEASE BE IN THE RIGHT SPOT!!!













Bugger, not enough length on the outward prongs, start again!!



Sealing up to make sure no dust or water works its way into the headstem:











Thought I should replace the plug while I had the bike apart too, lucky I did check it!!



So now with the Nav tower mount on, the bike can go back together:



Started making the side fairing mounts:























Got a suitable sticker made up for the bash plate:











Quite easily fit this in just one side of the bash plate:




Ok, so it was now onto the Nav Tower plates:











Light mounting:









Getting there!!

















Front mountings for the fairing:









Trimming the fairing to suit the lines of the bike/fuel tank:















Relocating the OEM instrument panel:









GPS mount/Roadbook mount:









Wiring and heated grip switch mounting:



12V outlet mounting:





Painting fairing:














So, the fairing is mounted from four simple screw head bolts, so it is easy to take on and off. I own a van, so it has to come off each time for transport.

It's maiden voyage!









Then it was time for a bit of stickering up to make it look the part:











Then it was off for 3000+ kilometres to test it all out. Performed flawlessley. Man I LOVE this bike!!!!

"Here is the resistor I used, because I had already run the bike without the EXUP plugged in, it had thrown the code and had the light on so I had to plug the EXUP back in, then disconnect and put the resistor in place, No more light!!"


Hi, guys! Recently I changed my stoсk pipe for LeoVince X3. That on the dashboard check engine lamp didn't burn, I installed the same resistor, in the same sockets, as shown in your photo. I used the resistor of 7,5 k/Om, capacity of 0,25 wt. But at me as before, the orange control lamp burns. I disconnected the minus ( - ) plug from the accumulator, but it didn't help me.

Help, what it is necessary to make? Perhaps, it is necessary to enter into the diag mode and somehow to erase this error No. 17 from memory?

Dude, I think your ready for an IED with that bash plate!

Very impressive.