2023/1986 TRX250R XC Build

Again, I wish I would have found a better platform to build off from, but it's what I have, so we're going to save it. The frame was gusseted previously, but the gussets seemed to be homemade and welded in very poorly. I decided to take a ton of extra time and remove all of the old gussets, which was a total PIA.

Here's where we started:







The frame is now with DBC Racing to install a new Pumashine complete gusset kit and re-powder.

I rebuilt all the brakes today. These components were all used and pretty rough looking to start; it’s amazing what vapor blasting can do. This is a complete TRX450R setup.

It’s been a while since I’ve provided an update. A lot of progress is being made, but nothing is done yet, unfortunately. I’m currently waiting on porting, case boring, gusseting, and powder coating.

However, I just received my new seat cover from Fourwerx. Here’s a little flavor of the blue brother theme that will be carried out with this build.


I also made it official by joining the AMA and registering for my D14 series. Of course I had to get the Honda version of the AMA card😊

In preparation for the 363, the entire bottom end has been completely redone by DBC Racing - new OEM bearings and seals, bored and powder coated cases, Hinson basket with OEM 89 clutch upgrade and Neil mod, and Hot Rods +4mm crank.

DBC Racing had the frame blasted, a Pumashine complete gusset kit tig welded in, and then everything powder coated by TLR. I went with Prismatic Powders ‘YZ Blue’ and Columbia Coatings ‘Black Mini Texture’.

Now I’m getting started on the reassembly… in the house😁 It’s MUCH warmer than out in my garage.

kellmx147 said:

Looks like it will be another great build. Good luck with getting everything together.
Now if I can only convince the other half to bring my next 250r build in the house…. lol

Cant wait to see the end result

Click to expand...

Thanks! I didn't actually ask mine... I brought the frame inside when I got it back from powder coating and just started assembling little by little. Then at some point it turned into full-on assembly and what you see now🤷🏼‍♂️😁 It's certainly been nice keeping it inside since it's been so cold out here in MI without a heated garage; otherwise, I really don't think I'd be this far along with the rebuild. I need to take it back out to the garage soon or it'll never fit through the doors without some disassembling.

Here's the latest progress.


I'm getting close to a standstill without having 3 critical parts - a steering stem, a swing arm, or an engine. I'm at the mercy of ISF on when he gets around to building the stem and arm, which it's hard telling when that will be. The bottom end is finished, but I'm waiting to have my ESR 363 CEO top end returned to me from the Selvy family. My hope is that they'll locate it and send it back soon, but I fully understand that they're busy with their own lives and grieving the loss of Rob, let alone tracking down all of Rob's customers parts and getting them returned.

There are small odds and ends that I can do in the meantime. One big thing that needs to get done, that I just can't get excited about, is trying to turn these nasty, old OEM fenders into clean, whiter riders. I had pretty great results with my first rebuild when I refinished my OEM fenders, but these are in much, much worse shape than the first ones that I started with.

This XC build is still on-going, but it won’t be ready in time for the start of the D-14 XC race series on May 21st, unfortunately. Or possibly the entire race schedule with how things are going. I still need a top end (🙏🏻 that I get mine back from the Selvy’s), no-link swing arm from ISF, and shocks from Motowoz. Since I haven’t gotten confirmation on the swing arm I haven’t even ordered the rear shock yet. The front shocks should be shipping any day now, though.

I’m still racing the series, but using my other 250R. I made some updates to help ensure it’s ready for the series - ditched the swing arm skid plate and added a Hess rotor guard and BCC sprocket guard, Cycra hand guards, and an 01 CR ignition.

We had a training/practice day yesterday - she ripped!

I realize that I’m way behind on updates. The blue XC build is still in-progress, so I’ve been racing the D-14 XC series with my red R. I’ve only been able to make 3 out of the 4 races thus far, but the R has performed beautifully. I’m racing C class being that it’s my first time racing. My three races have resulted in the following finishes: 2nd place/holeshot, 1st place/holeshot, and 3rd place. It’s been an absolute blast. Here’s some pics from the 1st race at the Fredneck Ranch in Frederic, MI.

Here’s some pics from the 2nd race at Bundy Hill Off-Road Park. There were polar opposite riding conditions on this course - where it was dry it was so dusty to the point you couldn’t see and where it was wet in the woods there were quad engulfing sized water holes. Thankfully I was able to avoid submarining the R in the water holes. Others weren’t as fortunate.

My third race was back at the Fredneck Ranch. I didn’t get the holeshot, but I blame that on poor line positioning. We initially lined up, where I was positioned where I wanted to be, then we had to move everyone back where I squeezed to the furthest outside location. Oh well, I still finished 3rd for the day.