Video: Simon Cudby
Text: David Pingree
Old motocross bikes out of the current model years that were once raced hard can end up in a heap of parts never to be raced again. Well, Jay Clark found just such a beat bike and went to work to make a off-road machine.
This bike was purchased as a full basket case from an ex-racer for under $1,000. (Summer time in California is the best time for good deals on bikes as it is too hot for most shoppers.) We feel we could have gotten this bike in great working order for under $2,000. With our initial investment we would have been under $3,000 for a great running fuel-injected trail bike.
I have always liked the Honda 250X for off-road and trail use, with the starting button being my favorite feature and the carburetor being my least favorite. So, the goal here is to make a full Trail/Off-Road fuel injected CRF270R/X. The main downside being of course that we wouldn’t have electric start. However, we were hopeful the larger motor, fuel injection, updated chassis, and suspension would have a good ultimate “budget” trail machine.
A cylinder Works 3.2mm over big bore kit drops right in. A stage one cam gives us plenty of grunt with not much loss of top-end power.
An FMF pipe with their most quiet spark arrestor insert kept us legal and happy to the ears. A Vortex ECU was able to be adjusted with just a few clickers. The throttle body was fully cleaned and modified by Wade at Injectioneering. He also softens up the throttle spring to allow for quicker action.
For the motor we had CrankWorks “heavy-up" the crank before the rebuild and balance to the piston. This cuts down on vibration and helps with a bit more trail tractability power.
For off-road and trail use the stock R tank would not get us too far so we used a much larger 2.9 gallon IMS tank that will now be able to go the distance. A Cycra full-coverage skid plate and hand shields were added to make sure we were ready for the trails.
Race Tech set up the suspension for slow trail use in very tight conditions.
For tires, we used Dunlop’s new AT81 tires front and rear for most use. However, we wanted to try a Dunlop D803 Trials tire for our dry, rocky SoCal conditions.
We also added a Pro Moto Billett Kickstand for ease on the trails.
Bike runs great on 91 octane pump fuel.
Not every modification is necessary for a good trail bike, but sometimes it's fun to play a bit, so Jay went all-out to make an ultimate trail bike.
Throttle Body Modifications
Complete Gasket Kit
Oversized Fuel Tank
Air4orce Air Boot
Full Coverage Skid Plate
Full Plastic Kit
Pro-Ben Full Wrap Around Hand Guards
Two-stage Air Filter
Formed Silicone Coolant Hoses in Yellow
High Pressure Radiator Cap
Stock Front Sprocket
Rear 48T Sprocket
997 Twin Walls
Dual Compound Grips
Brake Pads Front and Rear
AT81 Front 90/90-21 Trials Tire
AT81 Rear 110/90-18 and D803 Trials Tire
Custom Cool Seat Cover with Slightly Lowered Foam
Front Brake Cap
Rear Brake Cap
Oil filler Plugs
Ti Foot Peg Set
Fibers, Steels, Springs and Outer Cover Kit.
270mm Oversized Rotor/Adaptor Bracket 270mm
Complete Wheel Set
Front Steel Braided Brake Line
Rear Brake Pedal
All OEM parts Clutch cable, Rad Louvers and miscellaneous hardware.
O-ring Chain | Primary Drive
Freshen up the suspension with new fluids and seals
Vortex X-10 ECU and Mapping
Steering Stem Kit
Fork and Shock Rebuild Kits
Radiator modification welding, bracing seam welding and additional tank $250
Balance the Crankshaft
Custom Graphic set