New and Improved Honda CRF250R

Back in 2004, two-strokes were still the main go-to engines when it came to dirt bikes. The shift to four-strokes was one that many riders vowed they would never do, myself included. I swore I would ride two-strokes forever. 11 years later, not only do I love riding four-strokes both for off-road and motocross riding, I actually prefer them to the two-stroke bikes. There is just something I like about the easy-to-ride power of a four-stroke bike.

The CRF250R was one of those four-stroke bikes that came on the scene in 2004. Over the years this motorcycle has proven to be a winner and has been a mainstay in the 250cc class. We came upon a nearly-mint-condition ‘04 CRF250R for a steal of a deal as we were browsing Craigslist and had to jump on the chance to get our hands on this bike. Our $1,300 find looked to be in great shape and had obviously sat for the majority of its life. We couldn’t think of a better way to start a new project bike and had a ton of ideas we wanted to try out on it.

New Life to an Old Bike

A Vertex Stock Compression Piston Keeps This Bike Running Strong

The bottom-end appeared to be in great shape so we figured we’d shift our focus to the top. We wanted to keep the motor nice and easy to ride, while keeping it as reliable as possible too. We went with a Vertex stock compression piston kit and made sure to look over the valve train while the top end was apart. Luckily, it was in great shape. We did some other basic mods and maintenance throughout the top end to get everything running smoothly.

FMF Power Core IV S/A Silencer

We added the FMF Powerbomb header and paired it up with the Power Core IV S/A silencer. We love this combo because not only do they look good, but they are very durable and give great performance. The CV4 hose kit gives a nice pop of color to help accentuate the pipe too.

The CV4 Pipes Provide a Sweet Contrast to the FMF Powerbomb Header

When it comes to the carburetor, the ’04-’05 model is definitely better than the carb found in the later ’06-‘09 models, in our opinion. However, all model years seem to need some serious help in the jetting. For this build, we went with the Honda options NCYQ needle in the 3rd from top clip, a 50 leak jet, a 48 pilot jet, and two turns out on the fuel screw. We finished off by removing the backfire screen to help with the jetting. All of these changes proved to be a success with our carb for clean jetting.

We installed some new Hinson clutch plates to get our clutch working perfectly and polished that off with a Hinson clutch cover as well. When it comes to older bikes, I believe keeping things simple is best. We tried to follow our own advice by keeping modifications to a minimum. One of the main things to focus on is just going through the engine and other components of the bike to make sure that it has all of the important parts, and that nothing that could cause a failure or safety issue is missing or damaged.

Race Tech Freshened up the Suspension for Us

We left the stock suspension settings but we had Race Tech install some Pivot Works seals and oil into the fork and shock. Add a custom graphics kit from Attack Graphics and this bike is looking pretty sharp. Hard to believe it is really a 2004!

IMS Foot Pegs and a Tusk Brake Pedal Add an Element of Style

We added a lot of little accessories to make the ride a little more comfortable and to add to the aesthetics of the motorcycle. The IMS foot pegs look great and provide stable traction for the boot when out on a ride. The Tusk brake pedal is a durable replacement for stock that adds that little pop of color in the process.

Tusk D-Flex Handguards and Renthal Dual Compound Grips Are Awesome Additions

The Tusk D-Flex handguards are quick and easy to install and offer great protection not only from roost – they shield your levers when you go down as well. Add the Renthal dual compound grips, Works Connection perch and the bars, and we have a great look and feel to the bars.

The Tusk Oversized Front Brake Rotor Kit Upgraded Our Braking

The Tusk oversized front brake rotor kit and steel braided brake line with fresh fluid really helped us upgrade the braking action on this bike. The revised set up will last a long time and give us much more precise stopping power.

Works Connection Provides Great Protection

We changed the oil and filter on the machine and made sure that the drain bolts and threads were still in good condition. Then we added protection to the engine. We plan on being ready for anything our rides will throw at us, so we installed a Works Connection skid plate on the bike.

Better than Ever

Finished Product!

We gave the bike a final once-over – inspecting bolts to make sure they were correct, greasing pivot points, checking the brake pads, etc – and then we were ready to get this thing out for some riding. We’ve had a pretty good time so far testing it out and hope to have it run at least another 11 years. Let us know what you thought about the build and anything you would add to it or change!

Products Used

Cometic Top End Gasket Set CV4 Radiator Hose Kit FMF Titanium Power Core Silencer
Cometic Top End Gasket Set CV4 Radiator Hose Kit FMF Titanium Power Core Silencer
GPR V4 Fat Bar Stabilizer Kit Hinson Billetproof Clutch Cover Hinson FSC Clutch Plate and Spring Kit
GPR V4 Fat Bar Stabilizer Kit Hinson Billetproof Clutch Cover Hinson FSC Clutch Plate Spring Kit
IMS Pro-Series Foot Pegs Pivot Works Linkage Rebuild Kit Pivot Works Shock Rebuild Kit
IMS Pro-Series Foot Pegs Pivot Works Linkage Rebuild Kit Pivot Works Shock Rebuild Kit
Renthal TwinRing Rear Sprocket Tusk Aluminum Brake Pedal Tusk D-Flex Handguards
Renthal TwinRing Rear Sprocket Tusk Aluminum Brake Pedal Tusk D-Flex Handguards
Tusk Folding Shift Lever Tusk Front Motorcycle Steel Braided Brake Line Tusk Fuel Mixture Screw
Tusk Folding Shift Lever Tusk Front Motorcycle Steel
Braided Brake Line
Tusk Fuel Mixture Screw
Tusk Oversized Floating Typhoon Brake Rotor Kit Front Uni Air Filter Vertex Piston Kit Standard
Tusk Oversized Floating
Typhoon Brake Rotor Kit, Front
Uni Air Filter Vertex Piston Kit Standard
Works Connection Aluminum Radiator Braces Works Connection Axle Blocks Works Connection Engine Plug Kit
Works Connection Aluminum
Radiator Braces
Works Connection Axle Blocks Works Connection Engine Plug
Kit
Works Connection MX Skid Plate
Works Connection MX Skid
Plate

Don’t forget to pick up dirt bike parts for your next project at Rocky Mountain ATV/MC.

By Jay Clark