Another 86R Rebuild Thread!

[mohadib]

Yesterday after work I decided to repack my muffler. Next thing I know This happened.

http://i.imgur.com/EquGclc.jpg

I got this trike about 4 years ago. Here is what it looked like when I first got it (except for the bark busters)

http://i.imgur.com/53wNASC.jpg

http://i.imgur.com/DSQFwEI.jpg

After the throttle stuck on WOT one time, I figured I should overhaul it a bit. Here are a few pictures of that process

Old piston, really dodged a bullet there!
http://i.imgur.com/xTA3GuG.jpg

New bore, new piston.
http://i.imgur.com/nmwfcSS.jpg

More new stuff
http://i.imgur.com/Wjg5r2J.jpg

http://i.imgur.com/4n6uMAB.jpg

First start after rebuild
http://i.imgur.com/oVNCECe.jpg

http://i.imgur.com/L5aQQgx.jpg

Trike really came alive after the rebuild. But it needed new suspension. I put a Works shock on the back and progressive rate spring on the front

http://i.imgur.com/HhpCrtQ.jpg

Here it is with the new suspension and some new rubber

http://i.imgur.com/QVvhUSc.jpg

http://i.imgur.com/FLXQmQd.jpg


Now it's time to clean the trike up again. I have it mostly tore down right now. Waiting on parts. Plan on doing:

New crank seals
New water pump seals and bearings
New swing arm seals and bearings
Inspect the top end and see how its doing. Check the play in the crank while in there.
New shrouds
New stickers
New hoses for radiator
New chain and sprockets
New muffler - both exhaust hangers on the muffler failed when I landed a jump and I didnt notice right away, so the muffler got all beat up :\
Other odds and ends

I'll keep this thread updated as I go. Sure I'll have some questions for you guys.

Does anyone have a decent OEM exhaust hanger, the one with two bolt holes that goes on the top of the exhaust, they want to sell?
Will Mayer plastic fenders looks bad with my OEM tank and shrouds?
Got any suggestions for other things I should replace/check while I'm at it?

Thanks eveyrone for this site and all the help ya'll have been to me over the years!

[atc007]

Looks great. Maier plastic will look great.

[RPMRestorations]

Am I the only one that drools over the original tires...?

[Super350]

Am I the only one that drools over the original tires...?

No sir, in MHO theyre the best sport ATC tires ever made performance and looks... IM WITH YA!:cool:

[ONEBAD350X]

Am I the only one that drools over the original tires...? Nope sir, I do too haha!

[mohadib]

Got a press so I can rebuild the swingarm. Always wanted one :D Sure makes things a lot easier.
I bought this rebuild kit: http://www.ebay.com/itm/390667535454?_trksid=p2060778.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
One thing worth noting, this does not come with any of the bearings or seals that go in the bearing carrier. So now I'm waiting on that stuff to finish the swingarm.

http://i.imgur.com/vI2AZow.jpg

[mohadib]

I have noticed on my kick start assembly I seem to be missing two washers. Can anyone confirm that these two washers are infact a part of the 1986 kick start assmbly? ( the outer ones going on either side of #9 )
I only ask because in some digagrams I see, they are showing parts that I know only go on the 85r.

In this diagram they are #10, I dont seem to have either one of them... I might have lost them during disassembly, but I don't think so.

http://oi62.tinypic.com/ejv23q.jpg

Thanks!

[pantera1975]

Maier fighting red matches pretty good.

[mohadib]

I agree, after looking at some pictures of the fighting red fenders installed, I think they look pretty sharp and match much better than the other Maier plastics.

[Super350]

I cant say yes or no for sure but usually when parts or part #'s are in a bracket like that it denotes a change in design from year to year...say from 85 to 86

[BOB MARLIN]

There is something different in the kicker assembly from 85 to 86 and it does have something to do with that area. The 85's kicker started to "slip" after a while and it had to do with that spacer-washer area.

[Stingray]

According to the parts catalog #10 belongs on the 85R only.

[250rRoostmaster]

I have noticed on my kick start assembly I seem to be missing two washers. Can anyone confirm that these two washers are infact a part of the 1986 kick start assmbly? ( the outer ones going on either side of #9 )
I only ask because in some digagrams I see, they are showing parts that I know only go on the 85r.

In this diagram they are #10, I dont seem to have either one of them... I might have lost them during disassembly, but I don't think so.

http://oi62.tinypic.com/ejv23q.jpg

Thanks!

The 2 washers are used on the 85 motor only. They updated to a longer collar after 85.

[rdonald1979]

So can you run an 86 collar on an 85 without the 2 washers?

[250rRoostmaster]

So can you run an 86 collar on an 85 without the 2 washers?

Yes sir, no problem

[mohadib]

Thanks Stingray and 250rRoostmaster!

[mohadib]

I got my bearings and seals in for the big end of the swingarm. I greased up the bearing carrier and one of the bearings and started pressing the first one in. I have noticed that it slides in a few MMs at a time, kind of in a jerk. Its scraping the carrier walls very slightly and creating real fine shards of metal from the carrier. Is this normal?

I got the bearing flush with the outside of the carrier. Going tomorrow to get a socket big enough to set on the outside race and press the bearing in the rest of the way.

[mohadib]

The metal shavings are very tiny, like you see in this picture on the inside race

http://4.bp.blogspot.com/-18LSkDZjIPg/UjXGDlWkWKI/AAAAAAAAJy8/ltGB4hotOQk/s1600/IMG_3098.JPG

This is not my picture, I could not get my camera to focus on the shavings. Seem normal?

[250rRoostmaster]

If you heat the carrier and freeze the bearing they pretty much drop right in. When pressing them in they have to go in exactly square or you will end up with tiny shavings like you have possibly. I wouldn't worry about it, just as long as you pressed them in using the outside bearing race you should be ok.

[mohadib]

Made some progress today. Got my crank seals installed, stator, flywheel etc reinstalled. New seal for gear shifter. Just wanted to write a little on removing and installing the crank seals without splitting the case.

To get the seals out I first covered everything except for the seals with rags to keep debris out. Then I used a tiny self tapping screw to drill into the seal. I drilled really slow with next to no force behind the drill. I did not go all the way through the metal in the seal. I'd say I went 50% through. Stopping from time to time to remove any shavings. Then I took a really sharp awl and punched a hole the rest of the way through the seal (GENTLY!, just want a _tiny_ hole!). Then hand threaded in a big wood screw. Then I took a piece of wood and put it across the case to use as a fulcrum. Used a pair of vice grips to hold the screw and pry against the wood. Seals came right out. Then inspect the crank bearing area to make sure no shavings fell down into the bearing. If you dont drill all the way though and keep your work area clean, this should not be a problem. I also ran a magnet over the bearing hah.

Installing the new seals is pretty straight forward. Only thing I'll say about that is I went to Home Depot plumbing department with the seals to find pvc to work as seal drivers. Getting the seal completely seated and square took some time...
Also on the flywheel side make sure the seal is 6mm past flush.

Hopefully I'll have some more updates soon.

[Stingray]

On pressing new bearings into the carrier. I've read here someone used an old bearing as a driver after a bit of grinding to reduce the diameter.

Personally, I use the heat and freeze method mentioned by Roostmaster and never had a problem.

[mohadib]

I found a pvc pipe fitting at Home Depot that fit perfectly for the bearing carrier. Since I got the press now I didn't trying heating anything. Funny thing was installing the seal was more of a PITA than the bearing...

[mohadib]

Got the flywheel side back together. Now working on the clutch side. Figured I would replace the clutch while I'm in there. I see a lot of different compaines making/selling clutches on Ebay. Can anyone suggest a good one? Thanks!

[ONEBAD350X]

Got the flywheel side back together. Now working on the clutch side. Figured I would replace the clutch while I'm in there. I see a lot of different compaines making/selling clutches on Ebay. Can anyone suggest a good one? Thanks!

Oem honda is the best for clutch discs.

[yaegerb]

x2, OEM fibers and steels.