Father's Day= un-interupted Wrenching time. Uhh-Oh! The gift that keeps on giving!

[Mosh]

Happy father's day all..
Around here,basically Dad gets a ticket to do whatever I want, after a brief BBQ lunch with the family..:drool: Then followed by a nice evening BBQ dinner...:Bounce

So today, I am gonna complete phase 2 Of the wifes 250R repairs.

About 1 month ago, I was sick and tired of the oil spewing out of the exhaust flange due to a broken bolt on her 250R at the jug..So phase 1 was engine yanking and Top end job and some bolt extractions.
Much to my surprise the engine was bone stock..:naughty:
So a .20 over bore a Pro-X piston, exhaust flange repair and a CR headgasket, = nice dry engine with moo Powa!:twisted:
After a break in, I definately notice some massive clutch slipping in 4th gear coupled with the infamous 85 Kickstarter slipping...:rolleyes: No doubt compounded with the stronger compression of the CR headgasket.

So for phase 2 I bought myself some trike parts for a gift, and I will be digging into the the clutch and fixing up the kicker slippage and clutch slippage today..Since the R is known for the slipping kicker I figured I would document how I fix these..More on that later in this thread.

Wait...This is Father's Day...and here I am buying parts for "her trike" and fixing "her trike":lol:
Guess that is part of the duty of being "Pops"... Will post trike repair progress....More to come!
But, nice even trade off is she mows the yard while I wrench..That is a good deal IMO.:lol:

For those of you not familar with the history of this trike here is a crash course..
This what we started with in Labor day of 2006 in this condition here.
http://i100.photobucket.com/albums/m40/cosmicquads/250rright800.jpg
Twisted forks, bad plastic and bad jetting, but none the less still a good foundation.
1 year later, rebuilt forks OEM plastics and some carbon Fiber shrouds for testing looks, and a new seatcover coupled with some new fast Trekkers and a ESR pipe!
http://i100.photobucket.com/albums/m40/cosmicquads/250r800newpost.jpg
One more year passes and it is time for a RPM axle and carrier, Plus 3 PC'd 86 swinger and some Silver wheels.
This is pretty much it's current state..After the rear end mods.
http://i100.photobucket.com/albums/m40/cosmicquads/250rgoodies800.jpg
http://i100.photobucket.com/albums/m40/cosmicquads/250Rold800.jpg
http://i100.photobucket.com/albums/m40/cosmicquads/250rnew1800.jpg
http://i100.photobucket.com/albums/m40/cosmicquads/250rdone2800.jpg

[JohnnyBeGood]

That is super sexy. Im really diggin the red on red. Im restoring my 84r and i think i might model it after yours(cant find black plastics for it). Where did you get that seat cover and do they make one just like it for the 83-84 r's?

[Dammit!]

Where did you get that seat cover and do they make one just like it for the 83-84 r's?

Read his sig. :lol:

[Dirtcrasher]

Looking good without the gold, now that front rim needs some gold "removal"! :D

Yet another "Fathers Day Gift, uhmm, to her........" :lol:

[JohnnyBeGood]

Read his sig. :lol:

lol oops I didnt see that

[Mosh]

Ok tore into the ole girl and I knew I was in for surprises when I saw the RTV globs hanging from the sidecover from previous "repairs" if you will...
Keep in mind, I have never been into this engine except the top end and a stator cover.
As soon as the sidecover comes off what do I find?
2 Slut bolts in the basket...:wondering.. Ok now I KNOW for sure I am in for a good ole fashioned kick in the nuts!
Here we go....

http://i100.photobucket.com/albums/m40/cosmicquads/Repair/IMG_1242.jpg

After further investigation I find that I already have the updated kicker spacer in the kicker, but there is still slop in the kicker, so I will be dropping in a Almost new 89 TRX kicker cluster..
http://i100.photobucket.com/albums/m40/cosmicquads/Repair/IMG_1248.jpg
http://i100.photobucket.com/albums/m40/cosmicquads/Repair/IMG_1249.jpg
I also find that the counter balancer bearing is shot..So tomorrow at work I will press the gear off and install a new CB bearing..
http://i100.photobucket.com/albums/m40/cosmicquads/Repair/IMG_1243.jpg


Further digging into the clutch componest reveals a severly gaulded plunger that contacts the pressure plate and also a destroyed pressure plate boss for the plunger...Without that bearing all the clutch componeents were spinning and grinding on themselves and also causing a hang up that made the clucth slip in 3rd and 4th gear under full power.
http://i100.photobucket.com/albums/m40/cosmicquads/Repair/IMG_1246.jpg
http://i100.photobucket.com/albums/m40/cosmicquads/Repair/IMG_1245.jpg
http://i100.photobucket.com/albums/m40/cosmicquads/Repair/IMG_1244.jpg
http://i100.photobucket.com/albums/m40/cosmicquads/Repair/IMG_1253.jpg

Guess what?
Whoever worked on this clutch before, must have lost the ball bearing for the clutch pushrod.
So they put it back together less the ball bearing and that destroys the pressure plate, plunger, and pushrod, and you guessed it...The clutch arm as well..I am totally surprised that this sytem did not weld itself together..
http://i100.photobucket.com/albums/m40/cosmicquads/Repair/IMG_1255.jpg
So that is why the clutch has had some minor slippage since I have owned it..
Plain ole simple butchery, has yet ruined a perfectly good machine...But dont worry..I will fix it right!:drool:
Yep...a 19 cent part forgotten, has ruined almost 300$ worth of dicontinued parts...:(:rolleyes:
I just pi$$es me off to no end when I find this kind of debautchery.
So out comes my "slut 250R engine"..I used this engine for the spare parts I needed in the past and present..
I pulled out some good clutch parts..Pressure plate plunger, bearing, pushrod, and clutch arm..
Look at the difference in the parts and what is missing resulting in the $300 parts being ruined.
That damn 19 cent bearing forgotten or lost, combined with no service manual...Always equals garbage!
The parts on the top have been removed from the "Slut motor" I have in a bin.
Later that engine will get a new case and Longrod set-up.

http://i100.photobucket.com/albums/m40/cosmicquads/Repair/IMG_1260.jpg

So here is where I am at..
Tomorrow, I rebuild the counter balancer, clean and reassemble..
The kicker gears will get a new Pinion Spring, new big gear and new ratchet gear, an possibly a shim in the shaft if I deem it needed, to stop the kicker slipping..
The clutch will get the new components shown, with a HD clucth kit coupled with a easy pull lever.

Please guys..Always use the service manual..Failure to do so results in this type of carnage..
My Happy Fathers day wrench time has been altered by a nightmare of lost and fogotten parts and that DAMN RTV crap... But hey it could have been worse.