ATC 250R - Motor problems, please help.

[Stretch]

Hey guys, there seems to be a wealth of knowledge on this board. I've been searching through old topics for a while now. I just bought a 1985 (I think) 250 R. I guy was selling it in his front yard for $500 and told me that the motor had "just been rebuilt". A friend and I decided to split it and purchase it after a short test ride. We rode for 2 hours yesterday with no problems. Today after 1 hour of riding, the engine died and siezed up, wouldn't turn over.

I brought it home and started tearing it apart, and it turns out there was no coolant in the system. My fault, I should have checked it. It seems the piston skirt cracked and came apart on one side. Some pieces made it on top of the piston, other pieces fell below. After removing the top end and many pieces, the motor turns freely, but I need to split the case apart. I can't get the stator to come off. I tried using a 3-finger puller from AutoZone but it just wouldn't budge. I'm gonna try leaving penetrating oil on it overnight and give it a try tomorrow. Any ideas?

Thanks for the help!

http://members.cox.net/stretch3/waywrong.jpg

http://members.cox.net/stretch3/pieces.jpg

[Xowner]

wanna sell me that engine and you go buy a new one? :D



Good luck

[Stretch]

Here's what the top of the piston looks like. Gonna make a nice paperweight!

http://members.cox.net/stretch3/pistontop.JPG

[Stretch]

I'll consider it, but I really wanna fix it. Make me an offer if you like; stretch3@cox.net

-Jason

[mbg75]

buy the right flywheel puller. dennis kirk has it part number 28-282 for $19. 1-800-328-9280

[Stretch]

buy the right flywheel puller. dennis kirk has it part number 28-282 for $19. 1-800-328-9280

Thanks for the link. Any performance mods you guys can recommend while I'm in this thing?

[skippy]

yes if your going to split the cases.. replace the crank bearings and seals, check yr counterbalancer for any cracks on the tabs, check the crank rod for any excess play, buy a 89 clutch update kit, get all new exterior seals and get a oen honda complete gasket set right off the bat..

[J La]

What does the '89 clutch update kit do for you? How much is it?

[Stretch]

Thanks again for the input.

What's yall's favorite hookup for parts? I know ebay has some stuff in stock. 8)

[Stretch]

Here's the puller I'm trying to use.

http://members.cox.net/stretch3/puller.JPG

[atc86r]

The puller will cost around $13. Every cycle shop will have one. They fit alot of applications.

[Red Rider]

J La, the clutch update kit replaces the old style, 85-88, clutch push rod system that uses a steel ball. The update kit includes a new pressure plate, push rod, push rod end, needle bearing, & thrust washer. From what I understand, the old style system had a problem where the steel ball would wear the end of the push rod, which made the clutch hard to disengage & created excessive free play.

[whiteman350x]

Take it from someone who has been there, Get the right puller. Tried to to use a 3-jaw puller and ruined the crank and flywheel on an 85 r. Got the right one and it popped right off.

[Stretch]

Take it from someone who has been there, Get the right puller. Tried to to use a 3-jaw puller and ruined the crank and flywheel on an 85 r. Got the right one and it popped right off.

Will do. Thank you.

[Red Rider]

Stretch, nice find for the money! Sorry to hear about the bad luck already, especially since it sounds like it could have been easily prevented. Oh well, you were going to some wrenching experience on the R sooner or later, right?

[Stretch]

Yeah, I figured I was gonna have to get my hands dirty sometime. I found a puller (the right one) at a local junkyard for $15. Finally got that stator off. Now I just need to figure out how to split the case. It looks like I need a main bearing on the left side. :x