through the motor, we wanted to hear
it run for the first time in possibly years
or maybe a decade. After cleaning
the plug, it fired right up. After the
smoke settled, it was time to start disassembly and making a parts list.
Since we knew we were going to
have the engine worked on, so it was
the first item to be removed after the
bodywork was lifted and stored. Next,
the radiator was drained and the
chain was removed. The chain was
so old, the O-rings were falling out
with every rotation. The final step of
part one was to remove the engine.
It came out easy, but we then discovered a new issue. The previous owner
was a hack. There were mismatched
The engine will receive new parts from Hot Rods and CT Racing. They can build a
two-stroke engine to last and have the perfect engine package for us.
bolts everywhere and it had a bunch
of cracks in the frame. A new frame
gusset kit as well as a care package
from Specbolt was definitely added
to the parts list.
Our engine is going straight to CT
Racing. They have been building
250R engines since they were new,
and they have plenty of build options.
For us, they said the smart thing to do
is start with the bottom end. There is
no sense freshening up or even modifying the top end if you are still using
the bottom end that is 20 years old.
With the case split, they will install
a new Hot Rods crank, and while in
there they will modify the case, so
if we want to do a big bore later we
can. For now we will just go with
a simple over-bore using a Vertex
piston and get it running like new. It
will be fun comparing the two-stroke
power to today’s modern ATVs.
While the engine is being serviced,
we will finish stripping down the
frame and filling out the parts order.
Stay tuned in the magazine and on
our Facebook and Instagram pages
to see the progress. ❏
After removing the bodywork and
engine, we noticed there was a little
more work ahead of us. The frame has
several cracks in it and needs to be
fixed. We will weld on a Bare performance gusset kit and fix the other damage, then powdercoat it stock red.
It’s not likely we will end up with a 250R
this stock or clean-looking, but we will
try. If you are restoring your own project, guys like The Dirt Factory can help
you with some hard-to-find parts.