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  #121  
Old 07-11-2017, 07:10 AM
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Originally Posted by cowboyona426 View Post
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!
Yes, a lot of people are mad at photobucket right now. There was no warning at all from them, they just imposed a 399.00 fee for image hosting. I have all my original photos and lastnight I downloaded all my photos from photobucket. I will not being using photobucket ever again. I will setup a new account with another provider and repost all the photos.
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  #122  
Old 07-13-2017, 10:13 AM
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Default New Updates Coming

I just signed up with a new hosting service. I will add new photos of the build tonight and repost the old thread photos in the next two weeks.

The cases are assembled and the IMS transmission works perfectly. Getting ready to put the barrel on tonight!
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  #123  
Old 07-17-2017, 10:46 AM
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Default Engine Build

New Honda cases with the wide ratio transmission installed.



This was the last picture of the IMS Wide Ratio before the final installation.






Crank and wide ratio transmission turn smoothly and quietly.





Last edited by Moto7man; 07-17-2017 at 02:14 PM. Reason: add image
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  #124  
Old 07-17-2017, 01:57 PM
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Btw, just a reminder, this is where we started.



And this is where we are now,

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  #125  
Old 07-23-2017, 12:46 AM
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Default Finishing Up the Beast

I got a lot done on the engine today. I would have finished today but I didn't know that my top end kit did not come with a needle bearing. Rekluse EXP and Rekluse Torque Drive Clutch Pack installed today and a Boyesen Super Cooler and clutch and ignition covers.








---------- Post added at 11:46 PM ---------- Previous post was at 11:29 PM ----------



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  #126  
Old 07-24-2017, 09:52 AM
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Default Engine Assembly on the Beast.

Per Dogger, I ued a case splitter to set the seal depth on the crank seals and countershaft.



This is the cases before the clutch install with the spacer and bearing installed.


New recluse clutch basket.




New washer for the retaining nut.


These are the new Rekluse steel wedges for the clutch basket.



Steel wedges installed in new recluse clutch basket.


New Honda inner basket and pressure plate.


Inner basket holding tool.


Clutch nut torqued to spec.


---------- Post added at 08:52 AM ---------- Previous post was at 08:42 AM ----------

Right side case cover and Super Cooler assembly and Boyesen impeller installation. The impeller screwed onto the Honda pump assembly but be careful, the nut cast into the impeller is a std size and not metric, don't ask me why?


Super cooler mounted up. The cooler comes with its own gasket, so the two Honda gaskets with the metal separator plate are not used. Also, the kit comes with a black rubber cover and hose clamp that shut off the stock Honda return line.



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  #127  
Old 07-25-2017, 09:38 PM
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Default Power Valve Pinion Cavity Probe to Air Leaks?

I am getting ready to install the top end tomorrow. I have installed new bushings on each of the pinion shafts for the power valve actuation mechanism. I have read that there can be a air leak through the power valve pinion cavity unless the cavity is packed with moly 60. Is this correct?

Here is a photo from another site with the proposed fix.

Last edited by Moto7man; 07-25-2017 at 09:56 PM. Reason: add photo
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  #128  
Old 07-26-2017, 09:44 AM
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This is a very nice build! I do recall the manual stating that cavity has to be packed with grease, but I'm not sure on the reason why.
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  #129  
Old 07-26-2017, 12:12 PM
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Originally Posted by gusco View Post
This is a very nice build! I do recall the manual stating that cavity has to be packed with grease, but I'm not sure on the reason why.
Thanks for the compliment and the heads up on the grease packing. I will check my manual again tonight.
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  #130  
Old 08-04-2017, 10:16 PM
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I worked on the top end tonight. I used an 18mm Bux Tool to install the circlips on the Wossner piston. About 40 seconds a side to install the circlips with this tool!







The cylinder went on without a problem. I set the ring end gap on the Wossner "B" piston at .4mm.




Per Dogger's instructions, I preloaded the power valve at about .5mm.


---------- Post added at 09:16 PM ---------- Previous post was at 09:09 PM ----------

Brand new Honda head.






Finished engine! The goal is to drop the motor into the frame tomorrow!

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  #131  
Old 08-05-2017, 10:52 PM
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Default The Beast





I got the engine into the frame today.







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  #132  
Old 08-06-2017, 04:20 PM
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Default Las test Photos of the Cr250 Wide Ratio

I adjusted the Rekluse auto clutch, installed an RK Oring chain, filled the transmission with synthetic oil and filled the radiators with coolant.



I ordered a 120 Link chain. I used a chain breaker to remove three links, I am running 13/51 Renthal Gear Set, and a chain press to install the new master link.


---------- Post added at 03:03 PM ---------- Previous post was at 02:58 PM ----------

The yz450 brake pedal clear d the engine without a problem but I will have to find a different return spring.



I used Oetiker clamps on the coolant lines, they are very easy to install.



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  #133  
Old 08-25-2017, 09:49 AM
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Default 92-2001 CR250 Powervalve Air leak Fix

I just posted this in another part of the forum because I thought that it might get more exposure and save some people a lot of time and hassle.

I just tried this fix that I found on another forum by member T-Roy. I just finished my 94 CR 250 and I applied moly to the exhaust valve shafts and I packed the case cavities and installed new shaft bushings as well.

I checked my tool for leaks before the test. I performed a leak down test and I had leak. I applied soapy water to the head gasket, base gasket, intake gasket, power valve gasket, left and right main seal seals and both mechanical plugs that I used to seal the exhaust and intake. Not a single bubble, everything was torqued to spec and tight as a drum.

I then removed the main clutch cover and applied some soapy water to the lower power valve shaft in the crankcase. Bang! That was the leak. The soap bubble was about as big as a nickel then it would expand to the size of a quarter. I could pop the bubble and another one would form immediately.

Ok, here is the fix per T-Roy that does NOT require you to remove the cylinder. Remove the power valve cover, remove the spring clip(the one that goes through the hole in the top of the shaft.), remove the drive pinion(arm at top of vertical shaft), remove the spring, the bushing and the linkage.

Install a 6.8 mm oring.(Harbour Freight Kit see below for details.)Then slide the oring to the bottom of the shaft, reinstall the bushing, spring, drive pinion and spring clip. You may need to lift the top of the shaft with some needle nose pliers to get the spring clip to slide through the hole in the shaft. Push down a little on the pinion to press the whole assembly and put a slight pressure on the oring. Readjust your powervalve including .5mm preload on the spring per Dogger.

I put some extra moly into the oring and the bottom of the bushing. Here is what it looks like before reinstalling the pv parts. Per Dogger these engines should only drop 1 psi in 6 minutes. I retested mine after installing the oring. My engine only dropped 1 psi in 24 minutes!
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  #134  
Old 08-27-2017, 01:29 AM
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Default Finished Bike Today

I finished the bike today and she is a beast.













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  #135  
Old 08-28-2017, 08:01 AM
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Nice work, it must be a relief having it complete.
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  #136  
Old 08-28-2017, 09:08 AM
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Quote:
Originally Posted by cowboyona426 View Post
Nice work, it must be a relief having it complete.
Oh yes a big relief! I am very happy with the result. I am running a rad valve and a PWK AS with 175main, 52 pilot, needle R1369N. The guys at Boyesen said that with the rad valve I might have to go down about 1-3 jets sizes. My main is fine but I think I need to go to a 48 pilot, she is very rich on the bottom and I have backed the air screw out to 2.1/4 turns already.

---------- Post added at 08:08 AM ---------- Previous post was at 08:07 AM ----------

BTW, when you clean out the bottom a little, she sounds AWESOME.
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