The definitive 85R rebuild thread...

[riverrat]

Ok, here goes. Gonna make a rebuild thread, and try to include as much information as possible. I've noticed that some threads leave a lot of question to be asked. So what I am going to do, is divide the first four posts into:
1. Tear down
2. Motor rebuild
3. Chassis rebuild
4. Finished photos, video

Then try to include all the parts, places I got them, and threads I learned from here, to do this all. I will be updating this thread, as I go, and editing in what I did, in the first four posts, so you won't have to read through the entire thread to see what's going on. This will probably take more than a month to complete.

So here goes..first the link section, relating to tearing the bike down.
First off to start, you need a manual. You can get it here:
http://www.3wheelerworldforums.com/showthread.php?t=56218&highlight=manuals

Thank you Dammit!

Getting the swing arm bolt out:
http://www.3wheelerworldforums.com/showthread.php?t=69343&highlight=swingarm+bolt
http://www.3wheelerworldforums.com/showthread.php?t=36409&highlight=swing+arm+bushing

I soaked the bolt in PB buster for a hour or so. Then I put a puller, pressing on the nut end of the bolt, and pulling against the frame, while using an electric impact wrench to spin it for a while. Then a couple raps with a hammer, and it came out. I will have to rethread the end, if I want to re-use that bolt. Everyone says they are expensive, but I was wondering if you could just use a grade 8 bolt of the same size in it's place?

8/02/07 I started tearing down the bike tonight. I already had the motor out, so the rest came apart, in a few hours. I managed to get the rear suspension off, and the front forks, but did not disassemble them yet. Everything is off the frame, and I washed all the parts, and pressure washed the frame. I think, I am just going to look for some kind of epoxy paint, and paint the frame, instead of powder coating. My funds are not unlimited, plus, I want to ride the bike, and not worry too much about the finish.

This is the list of things I need so far, and I am open to suggestions as where to get, and what to use.

Rubbers under seat, on frame.

Grab bar (probably just use PRM: http://prm-atv.com/MN.asp?pg=products&grp=39&mfr=2

Rubber sleeve to hold electronics on

Chain and sprockets, was thinking: http://cgi.ebay.com/ebaymotors/Honda-250R-86-87-Power-Blue-O-Ring-Chain-Sprocket-Set_W0QQcmdZViewItemQQcategoryZ43982QQihZ010QQitem Z200086411561QQrdZ1QQsspagenameZWDVW

Brake lever

Radiator hoses

Foot pegs

Swing arm bolt, or equivalent replacement

Swing arm bearings and seals, or bushings from x.system (probably Honda, CDB motor sports)

Bolt kit

Top and bottom chain rollers


More pictures to follow, ran out of light tonight.

More info, as I go. Any info I get from replies in this thread, will be moved up into these first four posts

[riverrat]

Motor rebuild

Well my motor needs a rebuild. After some going through, I've decided to bore, and replace the piston, crank bearings, seals, counter shaft bearings, 89 clutch upgrade kit.

89 clutch upgrade kit:
http://www.3wheelerworldforums.com/showthread.php?t=70534&highlight=89+clutch+upgrade+kit

Counter shaft bearings, and info:
http://www.3wheelerworldforums.com/showthread.php?t=71229&highlight=89+clutch+upgrade+kit

Thinking of going with an ESR piston, ESR reed cage, carbon reeds, and some porting. I might do the porting myself.

ESR:
http://www.esr250.com/

I will get the bearings and seals from Honda.

[riverrat]

Chassis rebuild

Info on paint codes
http://www.3wheelerworldforums.com/showthread.php?t=71253&highlight=paint+codes

I will be painting the frame this week, if I can get the paint. Like I said earlier, I want to use some sort of epoxy.

For the rusted black colored parts, I was thinking of using POR-15
http://www.stoprust.net/?gclid=CM6Lk4mt2I0CFQILPwodjj1UnQ

I've used this stuff before with great success. You can paint it right over the rust. It is sort of self leveling, and can be put on with a brush. It almost looks like powder coating when it's down. I figure it would be good for the brackets that hold the radiators in place.

[riverrat]

Finished photos (to come)

[edog]

Well??????

[riverrat]

HeHe, well being that the lake never froze, and I missed a ton of work from being sick, I never got rolling on that project. I need some dough to finish the motor. By the summer I will have it going again. I haven't forgotten.