Category: Renthal

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FAQs

On an almost daily basis I get asked questions about the setup of my Honda CRF250 Rally that I’ve kitted out ready for my trip to Mongolia and what gear am I taking with me. Since I’m often asked the same question over and over I thought I’d put the definitive set of answers here in a blog post so that I can just refer everyone to the same place, so here goes!

Q: Have you made any modifications to the engine or exhaust to get more power? Are you using an EJK ECU? Have you fitted an FMF exhaust?

Simple answer is No.

I’ve not made any changes whatsoever to the engine, ECU, exhaust or any other component connected to the engine. I’ve deliberately kept the engine completely original so that I have maximum reliability.

When I purchased the bike I knew it only had 24HP and I am happy with that. If I’d wanted more power then I would had bought a bigger bike.

Q: What tank bag are you using?

I have fitted a Givi 6 Litre GRT706 tank bag that fits nicely on the tank and doesn’t get in the way when I’m riding in either the seated or standing positions. The tank bag is mainly for carrying my Canon 1300D DSLR camera and a map that’s visible in the clear plastic water proof top pocket.

Q: What USB device is that you have and where can I get one?

The dual USB and 12v socket with integrated voltmeter I picked up from Ebay. All the information of how to wire it into the AUX 12v feed already on the bike is in this post on the blog. For completeness I’ve also included the details of where you can get the 12v connector really cheaply.

Q: What folding mirrors are you using?

I’m using just a pair of cheap folding mirrors from Amazon.

Q: Have you fitted heated grips?

Yes! I was fortunate enough to negotiate a free pair of Oxford Heated Grips when I purchased the bike from my local Honda dealership. They really do get hot and are great in the winter months. All the information on how to fit and wire them to the CRF250 Rally can be found in this blog post.

Q: How will you keep your chain lubricated during the trip?

For many years I’ve used the Tutoro Chain Oilers on my motorcycles. The reason I prefer them is that they are simple to maintain, need no electrical or vacuum feed from the injection system and are really easy to fit.
I’ve already written a detailed post with photos on the oiler and how to fit it.

Q: What crash bars are they you have fitted? What skid plate do you use?

I use a great integrated skid plate and crashbar combo from Inpreda/GPKompozit. The bike has been dropped a few times on the trails now and it’s protected everything really well. The bash plate has also taken a few hits and has done a great job at protecting the engine sump.

All the information on fitting etc can be found on my blog post here.

Q: What pannier frame have you fitted?

I’ve fitted a Tusk pannier frame to the bike, it’s really solid and can handle the weight I’m going to put on it. All the details on fitting it correctly and the adjustments I had to make are detailed in my blog post here.

Q: What size Rotopax fuel canisters are you using?

Due to the cost I decided not to use Rotopax fuel canisters however, I do need to be able to carry extra fuel with me to make it between fuel stops on the trip and so after much research I went with some ChinoPax fuel canisters that I found sensibly priced on Ebay. They are really well put together and are very strong. They’re made from a very thick plastic that isn’t brittle and so they can take a fair amount of bashing. Noraly of Itchyboots fame uses the same cans and has dropped her bike on them many times without incident.
I got 3 x 5L canisters with fittings for less than the cost of 1 x 1 Gallon Rotopax can. Since the two front canisters will only be used on certain parts of the trip when fuel is difficult to get I didn’t see the point in spending a fortune on Rotopax cans when they would be empty most of the time.

I’ll also being using petrol to cook with and so the rear 5L tank will always have fuel in it so that I can cook at the end of each day. Full info on fitting etc is on the blog right here.

Q: Are you using hard or soft panniers?

I’m using soft panniers from Givi as I didn’t want the extra weight and bulk of the hard panniers. I looked at a lot of soft pannier options including the very cheap Lomo throw over bags but, eventually I settled on the Givi GRT709 Canyon 35L lockable soft panniers.

I really like the Givi soft panniers, they’re well put together, have a separate waterproof inner bag and have a separate water proof bottle carrier on the rear facing side of each pannier making it easy to gain access to drinks without having to open the main bag.

Q: What GPS are you going to be using on your trip?

I’ll be using two effectively, one on my iPhone in the Ultimate Addons waterproof case mounted above the instrument cluster and a Garmin inReach Explorer+ with SOS capability.
I also have a Garmin Zumo 350LM that I may take as backup but it’s worth noting that Garmin do not supply maps for Central Asia for the Zumo GPS units and you have to create your own using OpenStreet Maps.

Q: What side stand foot is that in your photos?

It’s another Chinese made item from Ebay I’m afraid. When it arrived it didn’t actually fit so I had to re-engineer it but, it fits perfectly now.

Q: Have you changed the suspension and if so what have you done?

Yes I have changed the suspension as the OEM suspension isn’t really fit for the kind of punishment I’m going to be giving it on the trip. There are quite a few options available suspension wise for the CRF250 series of bikes these days but I opted for the HyperPro uprated progressive spring for the front forks and a completely new custom built Hagon shock for the rear.

The difference these two changes have made is stunning! The bike now handles so much better and to date I’ve not managed to bottom out the front or rear suspension even hammering along the trails.

There are a number of articles on the blog with regard to suspension. Links to all the articles are detailed below:

General discussion on suspension and the options available

The Custom Built Hagon Rear Shock I purchased

Suspension upgrade, was it worth it?

Most suspension questions should be answered between those 3 articles.

Q: Does the Hagon shock reduce static sag? If so, what is the seat height?

Yes, the Hagon shock with the spring that I have along with the Hyperpro fork spring reduces static sag considerably. With the bike off the side stand and standing free without load the seat height is increased to 93cm (930mm).

Q: What tyres are you using on your trip?

I’ll be setting off on a pair of Continental TKC80s. These are great 50/50 tyres for road and off-road use. I am aware that people with high power bikes complain that they wear quickly on the tarmac but, on my little 24HP CRF250 this isn’t going to be an issue. Whether I’ll be able to get another pair of TKC80s as I travel I don’t know, so it may be a case of just buying whatever is available when they wear out. I imagine I am going to need 3 or 4 pairs of tyres over the duration of the trip so we’ll see what I end up using as time goes on.

Q: What hand guards are you using? Are they any good?

I’ve fitted a pair of Zeta XC hand guards to the bike. I like them because the plastic hand guard can be unscrewed and replaced if it gets broken and the aluminium mount bar provides great protection for the brake and clutch levers in the event of a drop.

Are they any good? Well they saved my hands a few times now from bushes and branches and the levers didn’t get broken in the falls I’ve had off-road so, I guess that must mean they are good.

Q: Where do you get your stuff from?

A multitude of places! Ebay, Amazon, local motorcycle dealerships, overseas … there are many. I’ve put together a list of suppliers on my suppliers page.

Q: Are you going to change the chain and sprockets?

Yes, I’ve got rid of the cheap and nasty OEM chain and sprockets and replaced them with a DID 520VX3 chain and JTS sprockets. I’ve kept the sprocket sizes standard, 14/40.

Q: Have you changed the handle bars and/or fitted bar risers?

Yes, both! On my first venture off-road with the CRF250 Rally it was immediately clear to me that I needed to raise the handle bars up a bit as I was having to lean over too much to reach them when standing.

I decided to change the bars for a better quality item as the OEM handles bars flex very easily and I could see them getting bent out of shape very quickly.

I decided to go with Renthal bars and a pair of adjustable 2in max risers. All the info is detailed in my blog post where I also detail the fitting of the heated grips.

Q: What cameras are you taking with you?

I’ll be taking 4 cameras with me, 2 x Crosstour 4K video/timelapse cameras mounted on the bike/helmet, a Canon 1300D DSLR with a selection of lenses and my trusty iPhone 7 Plus.

Q: What helmet are you choosing for your trip?

This is a good question! I’ve spent ages trying on different skid lids trying to find one that really fits me well and that isn’t too heavy or noisy in the wind. Time and time again I kept coming back to the Nolan N702X. I have a Nolan helmet for road riding and really like it and this 702X really works for me. It’s great in that it’s convertible so I can remove the peak if I want, remove the chin bar and make it an open face helmet and wear it with the visor or goggles. It just ticks all the boxes. The other great thing is that my Sena headset will also fit. Money now spent, I’m really pleased with my decision.

Q: Are you wearing KLIM motorcycle clothing for the trip?

Simple answer is No.
KLIM maybe nice clothing but it should be. At almost £2000 for a pair of trousers and a jacket they ought to be gold plated too!
I’ve been using RST motorcycle clothing for some time and really like it but, it’s a bit hot in the summer months.
After looking around and trying many different outfits on I opted for the Rev’It OffTrack jacket and Sand3 trousers. The reason I got the different trousers is that no one in Europe had the Offtrack trousers in stock and there wasn’t going to be another manufacture run until mid 2020. On the plus side, the Sand3 trousers are made of a slightly heavier material which should wear better especially when kneeling fixing punctures or repairing the bike. Both the trousers and jacket can zip together and have the complete 3 layer system meaning that in the really hot areas like the Gobi Desert I can remove the inner water proof layer and the warm quilted layer leaving me with just the thin outer shell with the back, elbow and shoulder protection.

Q: What tools are you taking with you?

I’ve based my tool pack on the tools I’ve needed to do the jobs on the bike during the preparation stage. I’m sure there are tools in the pack that others wouldn’t take and tools that others take that I’m not. It’s a personal thing and also takes into account my attitude towards risk which may be different to everyone else.

The above image shows all the tools that I’ve included in the pack so lets go through what we have here.

Spanners: 19/12/10/8mm.
Tyre Levers: 3 x including a Motion Pro tyre lever/ring spanner combo for the rear axle.
Allen Keys: 6mm Long and short, 5mm long and short, 4mm & 3mm Long.
Electrical Screwdrivers: Large, medium and small flat head and large and medium cross head.
Sockets: 17/14/13/12/10, 10mm Sparc plug socket, 17/14mm Hex for front axle, Bahco 1/4in socket set and 3 x socket to ring spanner converters so that I don’t need to take a socket wrench with me.
Electrical: Multimeter, cable/zip ties, insulation tape and a length of electrical cable.
Miscellaneous: Valve removal tool, pliers with wire cutter edge, stanley knife, Hagon rear shock C spanner, Tutoro priming magnet, plastic fuse puller and tyre pressure gauge.

I also have an electric 12v tyre pump and head torch that are not shown in the picture.

I also recommend you take a look at Matt Boyle’s video about his tool kit that he takes on his CRF250 Rally adventures.

Q: What spare parts are you taking with you?

I’m taking the following spares with me:

Complete clutch plate set and clutch housing gasket.
Front and rear brake pads.
5 x oil filters and gaskets.
1 x air filter
Front and rear wheel bearing kits
Head stock bearing kit
2 x spark plugs
Spare bulbs and fuses
Puncture repair kit
Spare inner tubes
Front and rear sprockets

Well I think that just about covers all the questions I get asked regularly online. If I have any more I’ll add them to this page.

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Fitting 2in Bar Risers and replacement Renthal Handle Bars with heated grips

After my first venture off-road on the CRF250 Rally the one thing I decided I needed to improve for the trip was handle bar comfort. Ideally I need the bars lifting a couple of inches or so. Being short in the arm I found the bars were a stretch especially when standing on the rough stuff.

After much thought I ordered some bar risers from Amazon, being cheap I correctly assumed they’d be from China and wasn’t sure what the quality would be like. After a few weeks they arrived and much to my surprise the quality was actually extremely good.

Whilst I was waiting for the risers to arrive I ordered a pair of Renthal handle bars from my favourite motorcycle shop, Orwell Motorcycles in Ipswich. The guys at Orwell Motorcycles really are good, James, Dan, Dave and the rest of the parts team are happy to do whatever research necessary to get me exactly what we want.

I wanted a pair of Renthal Aluminium bars that were as close to the dimensions of the original bars as possible and in no time at all James took the measurements of the existing bars and was happily trawling through the Renthal catalogue looking for the closest match possible. 20mins later the new bars were ordered and would be in later the same week.

Original Bars and the replacement Renthal Bars

The bar risers are designed to work with the standard 22mm bar or the larger 28mm bar. Since I’ve gone with the 22mm Renthal bar I’ll be fitting the risers with the supplied 6mm inserts in place.

Getting the bike stripped down ready to replace the bars and add the risers is more involved than you’d first think. It’s important to take photos of the controls on the original bars so that when you come to drill the holes in the new bars for the switch gear to mount to you know you’ve got them in the right place!

It’s important to make a note of the connections on the clutch and brake lever and also make a note of the angle at which the throttle cables exit the switch housing.

Once the switch gear, levers and original handle bars are removed it’s good to loose fit the new risers and bars to get an idea of how things are going to fit and look. The thing I really like about these particular risers is that they not only allow you to raise the bars but also tilt forward and backwards, this allows you to adjust the position of the bars perfectly.

Since I decided to fit some Oxford Heated grips to the bike this meant that I’d need to make some modifications to the bars and the throttle mechanism to accommodate the new grips. If you’re not fitting heated grips then you can ignore this part completely.

The standard throttle mechanism has a ridged grip tube, the problem with this is that it makes it too big a diameter to fit into the hard inner tube of the heated grips and so all the ridges need to be very gently sanded off with a very fine sanding wheel on a disc cutter tool.

On the left is the throttle grip tube once the original hand grip was removed and on the right the gently sanded down throttle grip tube ready for the Oxford Heated grip to go on.

Now that the ridges have been sanded off I refitted the right hand switch gear drilling the hole in the bar at pretty much the same place as on the original bar so that all the switches are in the same position.

It takes a bit of time to sand down the ridges to get the throttle grip tube really smooth for the replacement hand grip to slide on an off without getting stuck but it’s worth the effort. Don’t worry if the new grip is a little loose as it’s going to be super glued into place at final fit. Keep in mind that the throttle tube material isn’t particularly thick so make sure you don’t go mad with the sanding!

The left side of the Renthal handle bars has a knurled effect which has the side effect of making the bar slightly larger in diameter which stops the Oxford Heated grip from fitting. This is a real pain as it means that the bar will need gently sanding down until it’s exactly 22mm is diameter. This takes quite a bit longer than sanding the throttle tube.

I actually found it much easier to remove the bars again and sand the bar end down. This allowed me to work from the end inwards, trying the new hand grip for fit as I went. Go careful not to sand too much off.

Once the grip fits snugly remount the bars and fit the left switch gear and hand grip.

The mount for the Oxford controls comes with a bend in it, I had to straighten this out gently on an anvil and use a large wooden mallet to gently straighten the bracket without cracking it.

You will also need to do some work on re-routing the cables and brake line so that they reach the new bar height. There is actually a lot of slack on all the lines however, this is taken up by a tidying bracket that is mounted on the front of the top yoke. Removing this bracket and moving the cables around gives sufficient extra length that it’s not necessary to replace any of the cables or brake line, the standard are all long enough with a little sorting out.

The power for the grips needs to come directly from the battery as it needs a strong 5A feed. On the CRF250 Rally under the left front plastic panel there is a 10A auxiliary electrical feed however, we’re using this to power our phones, GPS and camera and so adding the heated grips as well would take the power feed almost to the limit when everything is on so another good reason to connect the heated grips directly to the battery.

Access to the battery isn’t straight forward on the CRF250 series of bikes as it’s not under the seat. Since we’ve also got luggage racks fitted it’s even more hassle getting access as the left side of the pannier frame needs to be removed too.

Getting access to the battery on the CRF250 Rally isn’t quick.

Once done and all back together the bike looks great. I also took the opportunity to fit a pair of Zeta XC hand guards to protect the levers and my fingers when off-road.

The small Givi tank bag fits nicely on the little tank of the CRF250 and is perfect for storing my Canon EOS 1300D DSLR camera so that I can stop, grab it and take pictures as we travel without having to get off the bike and open the panniers or a bag to get it.

I had a ride out yesterday with the new setup and it was great! It’s actually much more comfortable in the seated position now as the bars are just that bit higher and standing is a lot better as I’m not so bent over, it’a amazing the difference that 2in can make!