Thanks! Yes, the air dam is secured with the grommets to the frame in the front and then in the rear with the L-brackets provided by Maier. The air dam isnāt actually secured to the front plastic at all. Thatās what was so hard with trying to get it to fit together and look right, because the front plastic is āfloatingā above the air dam. Iām going to see if I can at least zip tie it in the front to better hold it together as one unit (like the OEM). It is secure, though, and not flimsy at all. I still need to get the lower fender brackets on, which will only make it sturdier. Iāll try to get some more pictures to show all of the mounting locations the next time Iām working on it.
2023/1986 TRX250R XC Build
The 250R addiction is alive and well over here againš
I had so much fun redoing and riding my Dad's 250R last year that I've decided to build another one specifically for XC racing. I've never raced before, but it looks like a darn good time. Sure, I could use my current 250R, but I've convinced myself that I don't want to ruin my Dad's old R through racing abuse. Besides, I really enjoy building them and turning nothing into something.
That said, here's my nothing. I picked up this 86 roller from Craigslist somewhat on a whim. In hindsight, I probably should have found a better candidate to start with, but it's my nothing now. Here's a picture from the Craigslist ad:
![Tire Wheel Automotive tire Hood Motor vehicle]()
I wish I had better and more pictures to show the before, but this is really the only one that I have with it all together. It's going to be quite the transformation, I promiseš
I had so much fun redoing and riding my Dad's 250R last year that I've decided to build another one specifically for XC racing. I've never raced before, but it looks like a darn good time. Sure, I could use my current 250R, but I've convinced myself that I don't want to ruin my Dad's old R through racing abuse. Besides, I really enjoy building them and turning nothing into something.
That said, here's my nothing. I picked up this 86 roller from Craigslist somewhat on a whim. In hindsight, I probably should have found a better candidate to start with, but it's my nothing now. Here's a picture from the Craigslist ad:
I wish I had better and more pictures to show the before, but this is really the only one that I have with it all together. It's going to be quite the transformation, I promiseš
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Unfortunately, Iām going to have some intake issues to figure out with this setup.
First, the carb is positioned directly into the frame. My ESR E1 cylinder on my red R didnāt have any issues like this, so there must be some slight intake geometry changes on the ESR E2 cylinders. I have a Sonny Fricia intake coming to hopefully correct the issue.
![Motor vehicle Automotive fuel system Automotive design Auto part Automotive exterior]()
Second is the intake boot and airbox, as both hit the shock. Iāve got a pretty good idea how Iām going to reposition the airbox further back, but the intake tube is going to be tricky. I found a company that only deals in intakes and intake accessories, so Iāve got a few different silicone couplers, reducers, and intake tubes to see what I can piece together. Iām hopeful that I can make something work, as there arenāt any off the shelf options any more. And the guys that built custom no-link intake setups arenāt getting back to me, unfortunately.
First, the carb is positioned directly into the frame. My ESR E1 cylinder on my red R didnāt have any issues like this, so there must be some slight intake geometry changes on the ESR E2 cylinders. I have a Sonny Fricia intake coming to hopefully correct the issue.
Second is the intake boot and airbox, as both hit the shock. Iāve got a pretty good idea how Iām going to reposition the airbox further back, but the intake tube is going to be tricky. I found a company that only deals in intakes and intake accessories, so Iāve got a few different silicone couplers, reducers, and intake tubes to see what I can piece together. Iām hopeful that I can make something work, as there arenāt any off the shelf options any more. And the guys that built custom no-link intake setups arenāt getting back to me, unfortunately.
I installed the Sonny Fricia intake along with the carb. The intake definitely helped the carb position issue.
![Motor vehicle Hood Vehicle Automotive design Car]()
![Blue Motor vehicle Automotive tire Automotive design Automotive exterior]()
I was also able to get the Selvy/KRP pipe with extended silencer installed as well, along with getting a few other odds and ends buttoned up.
![Tire Wheel Automotive tire Hood Motor vehicle]()
Iām still working on the carb to airbox intake and airbox repositioning. There has been a lot of trial and error, and ordering of different components to see what I can make work. With any luck, I should have the last piece delivered today that will let me get it all togetherš¤š»
I was also able to get the Selvy/KRP pipe with extended silencer installed as well, along with getting a few other odds and ends buttoned up.
Iām still working on the carb to airbox intake and airbox repositioning. There has been a lot of trial and error, and ordering of different components to see what I can make work. With any luck, I should have the last piece delivered today that will let me get it all togetherš¤š»
Now that I have my coolant leaking issue resolved, Iām back to trying to figuring out the Zeel ignition - coolant issue thread located here: Coolant Leaking Issues
I ordered the Zeel programming cable to better understand the maps and have the ability to update and adjust them, especially after hearing there are improved starting settings, etc.
Here are the two preprogrammed maps and settings from DRW - Map 1 is supposed to be TRX250R and Map 2 is supposed to be 01 CR250:
![Rectangle Azure Slope Font Line]()
![Rectangle Product Slope Font Line]()
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![Rectangle Slope Plot Line Font]()
I ordered the Zeel programming cable to better understand the maps and have the ability to update and adjust them, especially after hearing there are improved starting settings, etc.
Here are the two preprogrammed maps and settings from DRW - Map 1 is supposed to be TRX250R and Map 2 is supposed to be 01 CR250:
Well, I ended up getting a switch to have the ability to swap from Map 1 to Map 2 with the intention to get on a dyno to create custom curves. I wired in a rocker/toggle switch and added in to the bars. I ran out of room on the left side, so I found a spot to squeeze it in on the right.
![Tire Wheel Vehicle Automotive tire Light]()
Getting the switch and the rest of the Zeel wired up was one of the last things needed before firing it up. I got some fresh Sunoco 110 last weekend with the expectation to finally get some heat cycles in on this build.
With my first attempt at getting it started I experienced some wild kickback - kickback like I have never experienced before. I initially faulted the Zeel. I continued to kick and kick until I finally got it started. It ran, but boy did it run like crap and VIBRATE like crazy. Ughš I initially checked the woodruff key, thinking that the kickback caused it to sheer, but it all checked out ok.
I left it until this weekend, where I found the time and ambition to drain the oil and coolant and remove the pipe to get the clutch cover off and remove the clutch. Sure enough, therein lied the issue. There was a āmarkā on the counterbalancer gear that was mistaken for the punch mark for proper syncing with the crank.
![Automotive tire Motor vehicle Crankset Gear Bicycle part]()
This build has been one step forward, two steps back the entire way. Why would I expect anything different at the end?
Getting the switch and the rest of the Zeel wired up was one of the last things needed before firing it up. I got some fresh Sunoco 110 last weekend with the expectation to finally get some heat cycles in on this build.
With my first attempt at getting it started I experienced some wild kickback - kickback like I have never experienced before. I initially faulted the Zeel. I continued to kick and kick until I finally got it started. It ran, but boy did it run like crap and VIBRATE like crazy. Ughš I initially checked the woodruff key, thinking that the kickback caused it to sheer, but it all checked out ok.
I left it until this weekend, where I found the time and ambition to drain the oil and coolant and remove the pipe to get the clutch cover off and remove the clutch. Sure enough, therein lied the issue. There was a āmarkā on the counterbalancer gear that was mistaken for the punch mark for proper syncing with the crank.
This build has been one step forward, two steps back the entire way. Why would I expect anything different at the end?
Itās alive!!š¤
![Tire Wheel Vehicle Automotive tire Tread]()
It fired right up with no kickback, life is good again! I was really concerned that I had ignition problems, but it turns out when your engine is basically 180 degrees out of sync you get major kickback and poor starting/running conditions as well. The Zeel ignition works just as it should.
Itās still snowy and cold here in MI, so Iām going to wait on adjusting the jetting, etc. for another month or so. Iām just thrilled to know that when that time comes Iāll be good to go. I also want to consider getting it on a dyno to further tune it, TBD.
I still have several small things to figure out before itās completely done. All of my electrical checked out, so now I need to tidy up all of the wiring. The rear brakes wouldnāt pump up, so I need to figure out whatās going on there. Iām still waiting on a couple small things as well, e.g. poly guard for my swingarm skid plate, radiator overflow bottle holder, and turn down exhaust tip. I need to check/adjust the suspension as well.
It fired right up with no kickback, life is good again! I was really concerned that I had ignition problems, but it turns out when your engine is basically 180 degrees out of sync you get major kickback and poor starting/running conditions as well. The Zeel ignition works just as it should.
Itās still snowy and cold here in MI, so Iām going to wait on adjusting the jetting, etc. for another month or so. Iām just thrilled to know that when that time comes Iāll be good to go. I also want to consider getting it on a dyno to further tune it, TBD.
I still have several small things to figure out before itās completely done. All of my electrical checked out, so now I need to tidy up all of the wiring. The rear brakes wouldnāt pump up, so I need to figure out whatās going on there. Iām still waiting on a couple small things as well, e.g. poly guard for my swingarm skid plate, radiator overflow bottle holder, and turn down exhaust tip. I need to check/adjust the suspension as well.
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