The 1996 CR250 is the quintessential champion of steel frame CR250s. Many would argue that the dominance of the ’96 CR250 extended over other brands and even Honda themselves until the model’s discontinuation in 2007. However, one thing is certain: restoring a 1996 CR250 to its former glory is a monumental task by every measure.
It’s no secret that we have been rebuilding five of these 1995-1996 CR250s over the past couple of years. As the project finally culminates in the fruition of our laborious efforts, one cannot help but stand in awe of the beauty these restored bikes possess. Our DirtBikeTV edition, or “Black Knight,” is indisputably one of the most impressive, if not the most impressive, in the group. Featuring unique Decal Works chrome graphics that resurrect it from past obscurity, one cannot help but appreciate the striking beauty of this build.
Be sure to view our video on this bike! Jay delves into the build and offers some special insights!
We don’t like to pick favorites but Jay’s smile says it all for this incredible “Black Knight” CR250.
The engine and suspension were undoubtedly the most challenging aspects of this build. On average, it required two sets of suspensions to assemble one complete bike set and typically two to three engines to complete one. We maintain a bin of all the engine parts that remained unused after the engine assembly, which was expertly completed by Brad at Parapros. For the suspension, we had to discard any components that Race Tech found unusable for finishing our sets, as damaged suspension parts are futile on these older bikes.
Undoubtedly, one of the most distinctive parts of this bike is the custom “Factory” Gnarly pipe from FMF. The most frequent query about this pipe is, “Where can I find that rad factory finish pipe?” Regrettably, it’s not available for purchase. To achieve that exceptional finish, we had to acid dip the pipe to remove the chrome, after which Robbie from Robbie’s Pipe Repair polished the pipe, added some weld lines, and affixed a custom FMF badge to complete this masterpiece.
Similarly, FMF does not offer a Shorty for these models, so we crafted some custom Shorty silencers. For a detailed view of this process, watch the comprehensive build video of all five bikes, but a heartfelt thanks to Robbie’s Pipe Repair and our friend Dallas for making these Shorty Silencers a reality.
The tank on this bike was irreparable when we acquired it, so Clarke offers OEM replacement tanks for these models at a reasonable price.
MX Plastics was instrumental in meeting all our needs for this all-black build.
Naturally, on 30-year-old bikes, the seats and seat foams were worn out, so Motoseat provided us with new foams and an impressive cover to complement these remarkable Decal Works Graphics.
Wheels present a challenge in any of these older builds, especially if you’re budget-conscious. None of the rims were salvageable, but we invested considerable effort in restoring the hubs to accommodate Tusk Spokes and Nacstar rims.
Another significant element of this engine build was the clutch; the Rekluse TorqDrive not only enhances the bike’s modern appearance but also greatly improves its feel.
TMR– Cylinder porting and head mods with carburetor set up. Each Cylinder needed re-plating from Millennium to be matched to the Wiseco Piston.
ProX rod rebuild kits were used on the OEM cranks with Andrew Langston working perfectly balanced and assembled cranks as good or better than a new one.
Sano Metal Finishing has been one of the major contributors to the cosmetic aspects of these builds, assisting in the refurbishment of our metal pieces, the airbox, wheels, brakes, engine cases, and so much more that it’s impossible to list everything.
The ODI bars and grips perfectly complement the all-black aesthetic of this bike.
Also, don’t forget to watch our comprehensive build video of all five of these CR250s!
Immense gratitude goes to all the companies that facilitated this build. Check out the YouTube video for an in-depth detailing of the builds
In conclusion, the restoration of the 1996 CR250 motorcycles embodies a profound dedication to craftsmanship and heritage. Each component, from the meticulously plated cylinders to the custom-crafted silencers, reflects a commitment to excellence and a passion for bringing vintage machines back to life. The collective efforts of skilled technicians, combined with the support of specialist companies, have not only restored these motorcycles but have also preserved a significant chapter in motocross history. The “Black Knight” and its counterparts stand as testaments to the timeless appeal of the CR250 and the enduring spirit of the motocross community. This project, documented through detailed videos, offers invaluable insights and inspiration to enthusiasts and restorers alike, ensuring that the legacy of the CR250 continues to accelerate into the future.
Wiseco Performance Products
Pro-Lite Piston Kit
CV4 Hi-Temp Rad Cap
Rekluse
Core Manual TorqueDrive
Clutch Basket, Inner hub, Pressure Plate
Clutch Cover
Pro X Racing Parts
Connecting Rod Rebuild kit
Main bearings & Crank seals
Cranks seals
Carb rebuild kit
Clutch cable
Steering bearing kit
Front brake caliper rebuild kit
Rear brake caliper kit
Front master cylinder rebuild kit
Rear master cylinder rebuild kit
Front sprocket
Rear sprocket alloy
MX Chain gold
Counter shaft seal kit
Upper & lower chain roller
Swing arm bearing kit
Swing arm linkage bearing kit
Front and Rear rotor
Brake pads front and rear
TMR
Cylinder porting
Head Mod
Carburetor Slide mod & Jetting
Millennium Tech
Strip, re-pair damage & re-plate to stock size
Cometic Gasket
Engine gaskets
Langston Performance/Andrew Langston
Crankshaft rebuild with ProX rod kit
FMF Racing
Gnarly exhaust (stripped and factory treated from Robbies)
Shorty Silencer (Powercore Modified into a Shorty)
Dunlop Tire
MX34 Front
MX33 Rear
Race Tech
Suspension Re-Valve and set up
Hard Anodize of forks and shock body
Parapros Brad
Engine Rebuild
Carburetor Rebuild
Wheel Build/assy
Clarke Manufacturing
OEM style/sized Fuel Tank
ICW
Radiator straightening & bracing
Uni Filter
Two-stage Air Filter
DeCal Works
Semi-Custom Graphics kit
Preprinted number plates backgrounds
Sano Metal Finishing
Vapor Honing
Sand Blasting
Custom Cerakoting
MX Plastics
Full plastic kit
Mud Flap
Works Connection
Hour Meter
Stand
Front Brake Rotating bar mount
Brake Reservoir cap
Elite Clutch Perch Assy
Oil Filler plug
Stem Nut
MotoTassinari
V-Force Reed Cage
ODI
Emig V2 Lock On Grips
7/8 Bars
Galfer USA
Brake line rear
Brake line front
Specbolt Fasteners
Nickel Engine & Plastic complete bolt kit
Rear sprocket bolt kit
San Diego Powder Coating
Sandblasting, powder with super-durable clear, and “race prep masking’
VP Fuel
C12 Fuel
Nacstar USA
Black Rims
Tusk Off road
Front & Rear Spoke kit
Kill Switch
Tusk Shifter
SpD Factory Development
www.spdfactorydevelopments.com
Radiator Hoses
Radiator hose clamps
Chain Blocks
FootPeg Pins
IMS
Super Stock Foot Pegs
Fasst Co
Rear Brake Return Spring
Rear Brake Clevis
Klotz Synthetic Lubricants
R-50 Two-Stroke Pre-Mix & Chemicals
AK Technologies
3D printed Radiator Louvers
Motion Pro
Rim Locks
Turbo SE Throttle Housing & Cable
RM Stator
Stator
Coil
Carbon Solutions
Custom 3D printed in-frame cable holder
Enduro Engineering
Rear Brake Pedal Tip
Moto Seat
Seat Foam
Custom Seat Cover
Robby’s Pipe Repair
Strip, Buff, Factory look FMF pipe
Shorten PowerCore FMF into a Shorty
Jay Clark/DBTV bike builder
Parts to buy RM ATV/MC -DBTV Shopping
PODCAST: Podcast DBTV “That Moto Show”
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