Help! 280 kit for XR

[LWilson250]

HELP!!! I need to know what’s the best way to make my bike (1995 XR250R) into a 280cc woods machine! I am looking at the SRC 280cc kit; it comes with all the fixings! I was going to get that then take it to the Honda shop and have them bore the cylinder for me. Is this the best way to do it? What other ways are there to make the XR a 280? I have heard good things about Thumper racing. But I really want to keep this under $250.

Thanks!
Lee W.

 

[snaggleXR4]

Hey,
I've never had personal experience with big bores. However, Thumper Racing is known for good kits. Xr's Only also has good quality kits, as well as heavy duty valves/springs and cams that you may need to go with your 280 kit. Shop around, ask about warranty etc. Do a search on these DirtRider forums for XR280 kits. I'm sure you will get tons of info. Good luck.

 

[DualSportr]

Better bang for the buck is a 277cc kit. This one bores into your stock liner and still leaves lots of meat (no overheating problems).

The 284cc kit requires resleeving, so it's more expensive.

 

[LWilson250]

What will I have to do for Powroll to make my engine a 277? I am guessing I have to send the engine in. Do I have to send the whole engine or just the cylinder? What kind of costs are we talking about here? Has anyone had any problems with Powroll ever? After I get some more info on Powroll I will decide what to do, but it looks like I will be doing the 277cc mod. Thanks for the help guys.

Lee W.

 

[TexKDX]

Thumper's site will take you thru various options from just selling the parts to drop off the whole bike. They start at about $320 I believe if you send them your cylinder.

If you are the handy type, a local MC machine shop can bore your cylinder for about $60 and the piston kit from White Bros is $140. A shop manual is essential if you decide to do the work yourself and no special tools are required with the exception of a flywheel puller. On your '95 I believe the flywheel needs a mod, so you will have to send it out for modification or a core trade on a modded one. Thumper can take care of the flywheel.

The only way to keep it under $250 as you want to is to do ALL the labor yourself other than the boring and flywheel mod.

I did my '99 a few months ago. Not hard, but time consuming. Also lots of places where you can make errors, like dropping washers in the engine. Mine went off without a hitch, other than dropping a washer into the clutch side of the engine which required pulling the clutch side cover.

This is an easy project if you are a decent mechanic and have the right tools, like a GOOD torque wrench and the feeler gauges for setting the valves when done. A spare pair of hands come in handy for a few operations, like getting the cylinder back over the piston. If you can do a 2 smoke top end with confidence corrrectly, then doing the 280 is similar with the added complication of getting the cam back in right, dealing with the cam chain tensioner, and adjusting the valves.

OK, after re-reading your post I see you are in Cypress. If you decide to do it yourself, Kevin Stasny at K&S Cycles in Katy did my bore job. White Bros can sell you the stuff directly, or you can order it thru a local dealer as well that is hooked up with White Bros. If you are a TRH member, lots of dealers in the Houston area will give you 10% off parts and accessories.

If the do-it-yourself thing scares you, then you might want to get a labor quote from Kevin to do the top end for you. My guess is it would be $180-$250 in labor as it takes quite a bit of time to strip the bike down and pull the jug, then reassemble. While the head pipe is off I'd grind out the head pipe welds at the flanges. With the bike being a '95, you probably are due for a cam chain too. Heck, Kevin can get you the piston kit also and will probably be 10% off list. His work is very good - he was Colin Edwards' bike builder before Yoshimura picked him up and he still supports many a WERA rider.

Hope this helps,

 

[LWilson250]

Thanks Tex! The Honda of Houston guys said they would bore the cylinder for me for $50. If I were going to do all the work myself would it be worth it to get the SRC kit? The SRC kit comes with piston, pin, clips, head and base gaskets. Then could I just do it myself? Or if I buy the 277cc Powroll kit, could I do it myself? I am fairly mechanically inclined and I think I could do the work myself. And what kind of modified flywheel would I need? What exactly is the difference?

Lee W.

 

[TexKDX]

Lee,

Dualsportr can comment on the flywheel mod or you give Thumper a call to discuss. As far as the HRC kit, what do they want for it? You can get the same basic thing from White Bros with all the same parts, then add to that a base gasket and you are done. Their kit uses a JE piston.

I can't answer if you can do it yourself or not, Lee. That is up to you do decide. Like I said, it is not hard, but has plenty of opportunities to mess up. Putting the engine up at eye level helps a bunch, but it sounds like your back is a bit younger than mine ;) . I'd look into replacing that cam chain too while you are at it. Shoot me a PM if you'd like to chat on the phone about it, or maybe even arrange to ride my 280.

The motor does not have to come out. Getting it up at eye level is pretty easy if you want to make your own work stand out of 2x4s and plywood.

 

[DualSportr]

I typically don't say anything against other aftermarket companies, but I will say one thing.

Large re-sellers like White Brothers typically don't have access to hands-on technical help like smaller shops do.

They can sell products for cheaper prices, but won't spend as much time on the phone with you dialing it in after installation. They are also less likely to be able to walk you through solutions to problems.

Call White Brothers, ask them for recommendation on what works well with the bore kit, then call Thumper, SRC, and Powroll. I'll bet you get a much more inclusive answer from Thumper, SRC and Powroll.

I work for Powroll, so I know the R&D time we spend on each kit. If a customer experiences a problem with something, most likely, we've experienced it at some point and can help them out with one phone call.

I've worked with Gary at Thumper and Scott Summers (SRC) before, and both of these guys also know their stuff.

I'm not saying that White Brothers doesn't carry quality product, it's just nice to have technical backup when you need it!

 

[snaggleXR4]

Hey,
I have to agree with DualSportr about the knowledgeable service you will get with a smaller, more dedicated company. This is a prime example of how it's the little details that count. If you need expert advice, go with someone who can give it to you before and after the deal.

 

[TexKDX]

Look, the guy is wanting to save some $$ and do it himself. Should he really pay close to double for, in the end, the same size whole in the cylinder and the SAME JE PISTON????

Nice thing is there are lots of options for him. To each his own. My method worked for me and the Thumper route worked for xrsforever. I did mine the way I did for one main reason - I'd never had the top end off a fairly modern 4 stroke and wanted the experience. Right now I'm getting ready to split the cases on an Ossa. Could I send it out? You bet. I want to learn how to do it though.:)

 

[LWilson250]

I can't thank you guys enough. I have more then enough to think about now. I would like to do the work myself but... I just don't know.

Thanks again.

Lee W.


P.S. Tex, do you ever ride at Highlands?

 

[TexKDX]

Sure don't Lee. I ride up at the forest and at TRH's land lease south of Columbus.

 

[xrsforever]

Good info from Tex.I enjoyed the ride the other day Tex. Maybe I'll see you at the next TRH Family Enduro.:cool:

 

[LWilson250]

I just hope I can get my bike fixed in time for round 4 of the TRH family enduro series. I placed 34th in round 3. Not bad for my first ever enduro, and first ever ride in Sam Houston. I REALLY don't want to miss riding at Skull Creek, I hear it's the best riding within 100 miles.

Lee W.

 

[TexKDX]

Originally posted by LWilson250
I just hope I can get my bike fixed in time for round 4 of the TRH family enduro series.
Lee W.

What is wrong with it right now that needs fixed, Lee?

 

[LWilson250]

Ok, the bike is burning massive amounts of oil. So much oil that it’s oozing out the exhaust pipe like it’s a 2-stroke. The engine doesn’t have any snap, but I didn’t think XR’s were known for snappy throttle response. The main thing I an am worried about is the oil. The bike smokes really bad and not just during start up. It smokes all the time, I have checked the valves and they are fine, the only thing I can think of would be the piston.

Lee W.

 

[DualSportr]

Lee,

When you say you checked the valves, did you remove them, and check to see that the guides/valves aren't worn? This would be the first thing I'd check.

What about a cracked head? Check the area between the spark plug hole and each of the valve seats, this is sometimes the culprit.

Typically, that much oil will come from oil dripping down from the head, not being pumped up from underneath (as with bad rings), unless you have a broken oil ring (the corrugated part should have ends which butt up against each other, for a picture, check out the Powroll tech section on our website) - and this can definitely cause some serious smoking!

 

[LWilson250]

DualSportr, I have not done all the things you stated. I will check them asap! Thanks.

Lee W.