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  #101  
Old 03-23-2017, 08:53 AM
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Originally Posted by byronk View Post
Very nice!

i'm also interested in buying a domino throttle assy, does it bolt on right up using the stock rubber cover and the stock throttle cable?

Thanks
The stock Honda rubber cover fits fine. I am waiting for my Honda throttle cable to arrive and I will post an update.


Quote:
Originally Posted by crdude View Post
Looks awesome! Keep up the great work!

Iv been looking for this era 250/500 for a few years now to do a build as well, one will pop up some day I hope!
Thanks! It took me a while to find this bike but it came along and I bought it. Its taken a long time to run down all of the parts.

Last edited by Moto7man; 07-19-2017 at 09:45 AM.
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  #102  
Old 04-13-2017, 05:42 PM
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Build updates! New Galfer rear brake line, new UFO chain slider from Tuff racing,
New OEM Honda shock guard and rear disc guard, new FMF spark arrestor, new throttle cable, rad hoses and Honda fuel line and rad overflow hose.











These Milwaukee ratchets are the business. Makes everything go together much faster. Very fast and powerful.



Honda oem fuel line and petcock assembly with throttle and clutch cable installed.


Last edited by Moto7man; 07-19-2017 at 03:24 PM.
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  #103  
Old 04-17-2017, 01:57 PM
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Quote:
Originally Posted by Moto7man View Post
The stock Honda rubber cover fits fine. I am waiting for my Honda throttle cable to arrive and I will post an update.

---------- Post added at 06:53 AM ---------- Previous post was at 06:50 AM ----------



Thanks! It took me a while to find this bike but it came along and I bought it. Its taken a long time to run down all of the parts.
I just installed a Stock Cr 250 Motion Pro Throttle cable on the Domino throttle assembly and it fit perfectly.

Last edited by Moto7man; 07-19-2017 at 03:25 PM.
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  #104  
Old 04-17-2017, 02:11 PM
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Nice work it's looking good!!
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  #105  
Old 04-18-2017, 12:43 PM
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Quote:
Originally Posted by JERRY311 View Post
Nice work it's looking good!!
Thanks, I am almost ready to assembly the complete engine. I am just waiting some more parts to arrive.
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  #106  
Old 04-18-2017, 02:30 PM
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did you had fitting issues using OEM throttle cable with the domino throttle assy?

i'm thinking to get a domino quick throttle assy because mine has the '92 and the throttle grip goes a bit of a long way to reach full throttle...
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  #107  
Old 04-22-2017, 03:51 AM
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Quote:
Originally Posted by byronk View Post
did you had fitting issues using OEM throttle cable with the domino throttle assy?

i'm thinking to get a domino quick throttle assy because mine has the '92 and the throttle grip goes a bit of a long way to reach full throttle...
It fits perfectly, no problem at all. I used a motion pro stock cr 250 throttle cable.
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  #108  
Old 05-03-2017, 12:23 AM
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Default Do All PWK ASIs Have Venturi Winglets?

I got a new PWK carb today and I think that they sent the wrong one because there aren't any winglets in the Venturi.





[/COLOR]I also received my Rekluse Auto Clutch and Clutch Basket.

Last edited by Moto7man; 07-19-2017 at 09:44 AM.
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  #109  
Old 05-03-2017, 08:25 PM
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Case marks look like man made, hammer and punch to remove bearing ..!!, great job !! Don't give up !! Can't wait to see finished work , could I send you one of mine ???? Kidding , looks like you have a bit more work ahead .... Kudos friend .....
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  #110  
Old 05-03-2017, 11:36 PM
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Quote:
Originally Posted by bweighmaster89 View Post
Case marks look like man made, hammer and punch to remove bearing ..!!, great job !! Don't give up !! Can't wait to see finished work , could I send you one of mine ???? Kidding , looks like you have a bit more work ahead .... Kudos friend .....
Thanks! There is a bit more work but we are getting there!
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  #111  
Old 05-08-2017, 09:29 AM
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Default Received Correct Air Striker Carb

I returned the carb above which was a PWK standard quad vent without the Air Striker winglets in the venturi. I received my correct Air Striker Carb yesterday. I pulled it apart and check the jets and needle. It came with a #7 slide, 170 Main, 55 pilot and DDJ needle. I am running an FMF Fatty with an FMF SA, FMF recommends 175 Main, 52 pilot, R1369N Needle at 3rd position with airscrew at 1.5 out. This is what it looks like,


Winglets directing the airflow.

I had to press out the "starter gear" from the stock clutch basket. I used a spacer from my motion pro suspension tool and the old pressure plate(turned around) locked in my vice to push out the gear. it was tight but it came out without a problem. The Rekluse instructions specified heating the new Rekluse basket in an oven at 400 degrees for 15 minutes, and freezing the "starter gear", then push the "starter gear" into the Rekluse basket. I used insulated gloves from the kitchen, placed the basket on a piece of wood for support on the garage floor. I expected the bearing install into the Rekluse basket to be a pain, but the "starter gear" dropped right in without a problem.

Then I drilled out the rivets on the old basket to remove the stock ring gear. Note the grooves on the old stock basket, yikes.



Last edited by Moto7man; 07-20-2017 at 12:18 PM.
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  #112  
Old 05-18-2017, 12:15 PM
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Here is a picture of the Rekluse clutch basket with the CR starter gear and ring gear installed. I torqued the bolts and secured them with red locktite. I also peened the bolts with a punch. I think that it worked out very well. [IMG]





Two days ago I received a Wossner "B" piston with wristpin, clips and rings.




Last edited by Moto7man; 07-20-2017 at 12:47 PM.
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  #113  
Old 05-25-2017, 06:17 PM
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Awesome job Moto7man! Like Factory awesome! Had a question though, and this might have already been covered. Where did you get your seat cover? There seems to be no seam in the cover so it looks OEM. Is it? I too am restoring a 1994 and need a new cover in the flo red.

Thanks again!!
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  #114  
Old 06-12-2017, 10:35 AM
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Quote:
Originally Posted by Shiftyone View Post
Awesome job Moto7man! Like Factory awesome! Had a question though, and this might have already been covered. Where did you get your seat cover? There seems to be no seam in the cover so it looks OEM. Is it? I too am restoring a 1994 and need a new cover in the flo red.

Thanks again!!
Sorry for the late reply, one of my Subarus blew a head gasket, so I pulled the heads off to be machined and I got sidetracked for a bit. Thanks for the compliment! I bought the seat cover on ebay from a seller in Thailand. I was skeptical at first but when the cover arrived I was impressed with the quality.
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  #115  
Old 06-19-2017, 08:53 AM
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Talking Getting Back on the Build

I have gotten a little side tracked lately on some other stuff but I am back on the build now. I just got some more parts in and I will post some pictures tomorrow.
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  #116  
Old 06-20-2017, 09:18 AM
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Default Wide Ratio Transmission Ready for Installation

I want to thank Reddog-GasGasXC and the IMS guys for all their assistance. Their help was crucial in getting the transmission ready for the installation.

The problem was a typographical error on the older IMS instructions. This resulted in gears C1 and C3 being in the wrong positions. Once the positions were swapped on the counter shaft everything went together perfectly.


It is crucial that you follow the newer instructions on the right page for the countershaft.

A few more pics. Engine build to start ASAP.

Last edited by Moto7man; 07-19-2017 at 09:41 AM.
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  #117  
Old 06-25-2017, 11:22 AM
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Default Engine Build in Progress!

New shift side case.





New brake side case.







I checked the cases with a feeler gauge, they don't need to be machined, they are bang on tight.


---------- Post added at 08:31 AM ---------- Previous post was at 08:24 AM ----------

[/COLOR]New head still in the Honda Oem bag.


More parts stacked next the bench waiting to be installed.

[/COLOR]New Honda Crank.


The crank pressed in very smoothly. Wide Ratio IMS installed. Per Dogger's Instructions I checked the width of the two 23T gears, one on the main shaft and one on the countershaft to made sure the wider gear was on the main shaft to avoid any binding problems after the case halfs are assembled. Actually, on the wide ratio these two 23t gears are replaced with IMS gears and I checked on these per Dogger's instructions.

All bearings came installed on the cases, except for only one of the shift drum bearings. I'm not going to use the old bearing, even though it looks ok, so I am stuck until this new bearing arrives. However, the beast is coming together.




[/COLOR]Since I am waiting on the shift drum bearing, I started working on the top end.
This is the last NOS 1996 Cr 250 cylinder in North America.




Cylinder with new Wossner B piston.

Piston in the barrel.

Last edited by Moto7man; 07-20-2017 at 12:16 PM.
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  #118  
Old 06-25-2017, 03:06 PM
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Default Powervalve Installed

Install was fairly simple. I reused a few parts like the flapper but I replaced the cover and oring and the pivot that rides on the spring.


I used this brand of moly on the required pieces.

Last edited by Moto7man; 07-19-2017 at 09:40 AM.
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  #119  
Old 07-07-2017, 11:01 AM
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Looks like you overloaded your photobucket account. Same thing happened to
me and I ended up having to pay for additional space. Hope you can get the
pictures back up.
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  #120  
Old 07-10-2017, 09:38 AM
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Quote:
Originally Posted by dogger315 View Post
Looks like you overloaded your photobucket account. Same thing happened to
me and I ended up having to pay for additional space. Hope you can get the
pictures back up.
Photobucket is screwing everyone and making you pay if you want to use their site to post pictures to a third party site. I guess I'll be looking for another image hosting service since in my mind this is a form of extortion. Photobucket, you suck!
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