CRF250R Tranny Puzzle

[rbm33]

Originally Posted by Macho393

pss RBM I rode brock creek today(major single track). It was awesome!

man, i cant wait to ride brock creek im bringing jedi with me too!! give us a couple of months and jedi will be a lean mean cross country racing machine!!

[Coasty]

Well, I got the motor back together and in the bike. I just need to put in the cam, throw the carb on there, add some fluids and keep my fingers crossed. I wound up pulling the bottom end apart 2 times before I got it together correctly. First time the gasket was misaligned so I yanked it apart to get it straight, then the second time the countershaft didn't turn as freely as it should have so I pulled it apart and found the bearing was about 1/8" from being seated on one side so I seated it and it worked good. The whole thing really has been pretty easy and the shop manual is the key for me. I won't have time to mess with it the rest of the week but hopefully Saturday I can finish it up. Let me know how your doing with your bike Jedi. Your pics were also a great help, so thanks for that.

Patrick

[Coasty]

I wound up finishing it up tonight and the bike started on the 3rd kick. Not bad considering the last time it ran was almost 5 months ago at Cycle Ranch in San Antonio. Best of all, I had no extra parts

[Woody_393]

no extra parts is always a good thing. And it's running, even better

[crfjedi393]

FINALLY found the time to get busy putting things back together! Got a few pics to share. The motor is back in the frame and jr. can button everything back up tomorrow. It's not really that hard getting the bottom end back together. It's just time consuming. Especially since this was my first time. Hondas have quite a few bolts that are only 1 or 2 mm's difference and it's a trial-and-error game getting them all in the right holes. (Giving Satch some ammo there )
Anyway, the hard part is done and we will see if it fires up when the teenager is ready to do the rest. BTW, he is working two jobs this summer and mowing yards on top of that so I'm not knocking him in any way for not being that enthusiastic about getting the bike up and running. It's been +100 here many, many days this summer. Here's a few pics.

Placing the clutch basket.


Inserting clutch plates.




Flywheel and front sprocket on.


For anything that makes the crank turn as you tighten it, this is a good back-up.




Tightening the clutch.


This little rascal is just a tad troublesome. It's the kickstarter shaft and spring. You have to make sure both ends are in their proper slots and the center is seated over the shaft. Otherwise the right-side cover won't settle down as it should.


Finishing the top end.



Getting the little "engine that could" back in the frame.


BTW, it helps to slide the kickstarter on for something to hold onto.

It's in. Whew! Smooth sailing from here on out. (Well, as long as it starts.)


More to come when it fires up.

[RMZracer212]

welcome to my world, I do this everyday but with a little bigger motors, have the motor out of 2 4 wheelers right now. I will take a dirt bike over a 4 wheeler or street bike ANY DAY!!

Clay

[Coasty]

Agreed that dirt bikes are much easier than quads and street bikes. I put my engine back in minus the head to make it easier to get it in there. It really is a fairly simple deal to tear the engine apart as long as your organized and meticulous with getting all the washers and shims in the right spots.

What was your total monetary damage? Mine was $220. For that I got a gasket kit, new rings, countershaft bearing, seal and timing chain. I felt the crank bearings were low enough hours and wear I didn't replace those, the piston rings and valves were done about 15 hours ago but I still put a new set of rings on it. Hope it goes well for you and your son, he sounds like he's a hardworking young man and deserves to go out and play a bit.

[Woody_393]

Cool, sure feels good when it's all buttoned back up doesn't it. And it will feel even better when it starts.

Any left over parts?

[crfjedi393]

Originally Posted by Coasty

What was your total monetary damage?

I'd have to add up the receipts but in my head it comes to just a bit over $300. He bought all new bearings, seals, and gaskets. The piston and rings don't have many hours on them.
And yes, Clint is a worker. He knows the value of a dollar and I'm proud of him. For a 16-year-old he spends his money pretty wisely.
No left over parts so far. Fingers are crossed.

[crfjedi393]

Finally done! Buttoned things up late afternoon and we rode until 11:00 tonight.



Details:




No bolts left over! This brought a HUGE smile to my face!


It busted off on the 4th kick and I can't tell you how pleased I was to hear it purr. He ran a couple of laps at our local track and checked all the bolts. Then wrung it's neck like some of you know he can.

[FFRacing11x]

Look at that!!! FFR airbox mod stock right from the factory Who says the big guys don't read ATM

[char393]

Congrats on getting the job done!

Thanks for keeping this thread updated with pics. I really think it ought to be moved to the knowledge base.

[Woody_393]

Agree'd char. Great info for sure.

[Aus_Rider_22]

Fine thread, David

Should be a good resource for others doing a tear-down on there 4-stroke!

[hale701]

This just helped me change out my low end and top end. Reason: Trust washer in a million pieces. Thanks for taking all the pics!

[jason33]

hey jedi-
i noticed your clutch basket has -chatter marks (grooves) wore in the tabs, you might want to take it apart and file them smooth again ,or you will end up having a grabby clutch, and will end up needing to do it any way
- it keeps the plates from sliding in and out propperly,and if they get too deep it will lock up the clutch,=no slipping--
just a sugestion-