rebuild time

[Allison55ex'er]

figured I would start off by posting a picture of are trip to Rose City.

http://i603.photobucket.com/albums/tt116/Allison55/250r007.jpg

Its a very fun place to ride you can find a little bit of everything there. This is a picture of the quads by a fence that is blocking off what used to be a very fun hillclimbing spot. Very Pissed Off

http://i603.photobucket.com/albums/tt116/Allison55/250r008.jpg

but anyways now I have to tear down cause my clutch has been slipping and it is a hard pull do to the grooved basket

http://i603.photobucket.com/albums/tt116/Allison55/250r012.jpg

I removed the pivot bolt very easily after soaking it with PB blaster on and off for a couple weeks I will never beat the crap out of one again without doing this.

http://i603.photobucket.com/albums/tt116/Allison55/250r013.jpg

halfway through teardown

http://i603.photobucket.com/albums/tt116/Allison55/250r014.jpg

pulled the motor and found that almost all the clutch cover bolt threads were gummed up which leads me to my first question what is the best way to fix them im geussing im going to have to drill and retap to the next size up and get new bolts.

http://i603.photobucket.com/albums/tt116/Allison55/250r016.jpg

I also noticed that the shifter shaft moves quite a bit in and out Im wondering how much is normal and when i push it in it makes my clutch basket move in and out

http://i603.photobucket.com/albums/tt116/Allison55/250r017.jpg

any input will be appreciated

[thedeatons]

I replaced most oof my clutch cover threads with Keinserts from a local Fastenal. They will tell you the drill size to drill to, then you tap the holes for the Keinserts, thread them in, then tap down the keepers.

Keinserts are WAY better than helicoils or standard aluminum threads, because they cannot come out once inserted. You can torque the screws quite a bit with Keinserts too. It is in my opinion the best fix for this kind of thing, although not the cheapest.

I believe the Keinserts I purchased were for an M6 screw (standard clutch cover screw). The OD threads are an M10, which is what you have to drill and tap for before installing the Keinserts. Theey cost about $6.50 each, but are well worth it.

I can provide you more information if you need it.

James

[Allison55ex'er]

alrighty I dont think we have any fastenals around here but I will see what I can find out tomorrow. Im also going to be taking off my top end my compression is pretty low hopefully I dont have to bore it.

[thedeatons]

Try www.mcmaster.com. They have super fast shipping and sell everything...

Catalog page 3232. Metric Key-Locking Threaded Inserts

ID will be M6 x 1, OD will be M10 x 1.25.

Part number 90245A171.

Don't let them trick you into getting an installation tool. They screw right in, and you can tap/hammer the keys down easily. Those "keys" push through the threads and don't let the insert turn ever again...

James

[IcutMetl]

I'll go right along with the keyinserts vs helicoils. I used to use them all the time repairing thermo-form mold bases and trim die sets. McMaster Carr is a great place to find them if you don't have a Fastenal or industrial supply place nearby. A company in Cleveland (Jergens) also makes them.

[Allison55ex'er]

I appreciate all the help guys your makin it real easy for me. Today I took off the cylinder and it appears to be slightly ovaled out so i tryed measuring it and didnt find anything out but my piston says 1.00mm on the top so i geuss i got like 3 bores left. I was hoping that I would be able to get away with doing just the clutch but I wanna do it right even though it will set me back quite a bit. Tomorrow hopefully I will be able to get some pics cause I think it might have a little bit of a cleanup portjob.

[cdrookie]

what do you mean by "gummed up"? to me it sounds like they're some silicone in them? if they're stripped a keinsert is overkill, and tapping the locking pieces down in can result in breaking the case. a helicoil will work fine, not like you're torquing the hell out of those small bolts anyways.

[Allison55ex'er]

Ya basically all of the threads are stripped out

[Allison55ex'er]

I just got some pictures of the cylinder and I was hoping someone could tell me if it was ported or not cause i have no idea. I'm definetly new to all this
http://i603.photobucket.com/albums/tt116/Allison55/250r025.jpg
http://i603.photobucket.com/albums/tt116/Allison55/250r026.jpg
http://i603.photobucket.com/albums/tt116/Allison55/250r021.jpg
http://i603.photobucket.com/albums/tt116/Allison55/250r022.jpg
http://i603.photobucket.com/albums/tt116/Allison55/250r023.jpg
How much side to side movement can you have on the rod. I couldnt find anything for this in my manual
http://i603.photobucket.com/albums/tt116/Allison55/250r024.jpg
Im all ears to anyone that wants to chip in

[Allison55ex'er]

After looking at that last picture i posted then my motor it looks like the left hand case is alot newer it must have been replaced. The previous owner had no idea what was done to it so its kind of exciting yet scary to see whats goin on in there. Maybe I got some yukons in there lol. I also found that it has the 89 upgraded clutch and it looks like the basket has been filed once already.

[cdrookie]

hard to tell, pics have too much glare, the intake and exhaust may have been cleaned up, but the transfers look untouched.
the rod should have ZERO up and down movement, they usually flop around a good bit side to side.

[Allison55ex'er]

ya it doesnt have any up or down movement so I think its good. Where would be the best place to have my cylinder honed and possibly bored I think the best place around here would be the honda shop?

[thedeatons]

I sent my stuff to Tom, owner of Pro Designs, who makes the Cool Heads. He checked everything, honed the cylinder, and made a new pump gas dome. The charge for everything was ~$115.

Keinserts are easy to install. I have done a LOT of them, and never cracked a case, or anything else for that matter. They are the most permanent solution hands down.

James

[Allison55ex'er]

well I think if I am gonna send my cylinder somewheres I would send it to Neil, and it sounds like Key inserts are the way to go. I will keep on updating this thread even if it takes a while to get things goin. thanks for all the help.

[Allison55ex'er]

Figured I would bump my thread back up cause i havent been on in a while but it was for a good cause.
http://i603.photobucket.com/albums/tt116/Allison55/250r038.jpg
http://i603.photobucket.com/albums/tt116/Allison55/250r027.jpg
http://i603.photobucket.com/albums/tt116/Allison55/250r028.jpg
http://i603.photobucket.com/albums/tt116/Allison55/250r029.jpg
http://i603.photobucket.com/albums/tt116/Allison55/250r030.jpg
http://i603.photobucket.com/albums/tt116/Allison55/250r031.jpg
http://i603.photobucket.com/albums/tt116/Allison55/250r032.jpg
http://i603.photobucket.com/albums/tt116/Allison55/250r034.jpg
http://i603.photobucket.com/albums/tt116/Allison55/250r036.jpg
http://i603.photobucket.com/albums/tt116/Allison55/250r037.jpg

[Allison55ex'er]

It turned out to be a really nice day, and this is the first time I have got to watch the pro's so it was pretty cool and I learned alot. Wish I would have been able to take more action pictures but I'm just not very good with the camera. My stepbrother rode his apex in a couple of 90cc classes and got I think a 7th and an 8th overall which is pretty good considering we dont have very much money into the quad. I was happy to see at least two 250rs that I know of out there and a few hybrids but there should be more. I definetly want to go next year.

[Allison55ex'er]

Does anyone know where I can find some stock red colored spray paint that I can touch my frame up with while I have the motor out. My brother is going to be welding some cracks on the steering stem mount and there is some rubbed off where I dont want it to rust anymore. I checked rockymountain for the pj1 stuff but all they had was black. thanks

[yellowzo3]

the action pics look good man! the track looks perfect too :cool: ...did they shut down that hillclimb because everyone was riding on it or was it for another reason? You might want to just go for powdercoat instead... once its blasted they'll be able to see any other cracks or anything thats wrong with it... I'm sure Pappy can get you pretty much an exact match to that red if you want... or you could get any other color you like.

[Allison55ex'er]

I dont think that little hillclimb was very popular and it wasnt very hard but it was a real good spot to cool down and have a little fun its kind of one of my favorite spots and i dont know why they had to close it down I was pretty dissapointed when i seen that fence. I want to powdercoat my frame during the winter but right now i just wanted to touch it up over the welds I dont really have the time or money to go all out on it just yet. I plan on getting new rings, hone, wrist pin, head gasket, pretty much all the obvious stuff then a hinson clutch basket, and do neils clutch mod.

[Ruf Racing]

WOW, that track is sweet. Love that kind of backdrop. :)

[Allison55ex'er]

Ya the track is really cool I like how the hole thing is layed out as far as parking and everything I wish I would have been able to ride there.

[Allison55ex'er]

I got the clutch basket off and this is what I found
http://i603.photobucket.com/albums/tt116/Allison55/250r039.jpg
It has the two needle bearings
http://i603.photobucket.com/albums/tt116/Allison55/250r040.jpg
But im confused because the collar is an 86 according to my manual not the other style that it shows in there
http://i603.photobucket.com/albums/tt116/Allison55/250r041.jpg
And I dont know if there is supposed to be a washer in between the 2 needle bearings like the manual shows because there wasnt one on there.
Also Im wondering how much wear there can be on the outer splines of the inner hub
http://i603.photobucket.com/albums/tt116/Allison55/250r042.jpg
Should I order my hinson parts directly from hinson or is there better prices to be had?. thanks guys