250-500cc 2009 WR300 Refresh / Ice build

[R. Stephen]

Well I picked up a 2009 WR300 to build up for our upcoming ice season here in Wi. I normally run one of my 449/511 bikes, but time to try something different this year. I picked this bike up for the right price with all the right parts but man I've never seen a bike in worse shape. I don't think the previous owner had any business owning a dirt bike, but any how here is the final product. I'm almost done with it now. Rebuilt the whole bike from top to bottom.

 

[R. Stephen]

A few build pics along the way

 

[Jhunter]

Lots of questions. Where did you get the plastic frame guards? Did you repaint the wheels black or just add rim stickers? I see you painted the swing arm and frame, any special paint or special prep? - Looks Great IMO

 

[R. Stephen]

The frame guards came on the bike. They look like one off custom guards out of thermal plastic. I just cleaned them up and sand blasted them for an even finish. Everything on the bike was powder coated. Stripped, sand blasted, and etched before coating. Regular paint of any sort will never hold up in an off road environment. The wheels are off my old WR250 they were powdercoated as well and rim striped added. I will never powder coat rims again only anodize from here on out. it just does not hold up very well. It's fine for a few years but it will eventually chip from tire changes.

 

[rschneider]

The frame guards look like the ones from P3, as far as I know they are no longer in production.

 

[Motosportz]

niiiice...

 

[juicypips]

We need an (i love it!) option thats a sweet looking bike now, so what was so wrong with previous works on it?

 

[darealickt]

Well I picked up a 2009 WR300 to build up for our upcoming ice season here in Wi. I normally run one of my 449/511 bikes, but time to try something different this year. I picked this bike up for the right price with all the right parts but man I've never seen a bike in worse shape. I don't think the previous owner had any business owning a dirt bike, but any how here is the final product. I'm almost done with it now. Rebuilt the whole bike from top to bottom.

View attachment 47608View attachment 47609View attachment 47610View attachment 47611

Wow! What forks are those? Did you have the black 50mm Zokes anodized that color? Or are those different forks altogether?

 

[R. Stephen]

I anodized the forks when I rebuilt them 50mm Marzocchi. Its a unique flat red I really like. I did my marchi wheels that color and have been hooked ever since.

here is a before photo after I washed it the first time. It then got washed 10 more times before dis-assembly.

 

[R. Stephen]

 

[HusqRacr]

Wasnt sure if I'd like the 449/511 front fender on there...but Damn, that did it for me. New fender on order for my 300

 

[Motosportz]

Wasnt sure if I'd like the 449/511 front fender on there...but Damn, that did it for me. New fender on order for my 300

As you can tell I like that fender as well...

 

[ray_ray]

You made the black subframe, SA, and frame work together... Everyone can't really say that ...

 

[R. Stephen]

Well me and a friend gave the 300 a whooping today in the dirt and looks like its time for a top end. I heard a little noise and killed it right away after about 30 mins of hard moto. So put this one away and took out my 449 instead.

 

[juicypips]

Whats wrong with that? Looks like a stain from where the pistons rested in the cylinder.
Come on tell us tell us

 

[shrubitup]

Beautiful bike however you should add a case saver instead of that stock CS cover

 

[R. Stephen]

Looks like the piston was slapping the cylinder wall on the intake side. There are witness marks on the piston and cylinder wall. I still need to measure up everything and get a parts list together. When you guys are rebuilding the top end on these bikes what is usually replaced? I'm going to have Eric Gorr do the cylinder and throw in new piston, rings, pin, upper rod bearing, ect.....

 

[Auto5guy]

 

[juicypips]

Thats it all listed there.

 

[R. Stephen]

Well got the cylinder and head back from porting and they look great except one issue....... I began putting the Husqvarna together this morning and the piston does not appear correct. The rod bearing does not fit in the piston. The walls of the piston are too close together to allow the bearing to slide in. Also it is quite a bit different in height, ring location, and shape than the previous piston. So time to talk to the engine builder and see what the deal is. bummer.