Bearing removal

[Banshee330]

Thanks , I checked Ronnie’s mail order under 1987, it showed the part but it skipped it on the available parts list. Done the same thing on Rocky Mountain. Then checked 1989 and it showed up 🤔. I know the motor serial number has 87 at the end. I just bought a lot of parts hope I am buying the right ones. Does any one know if this bearing is used on 87?

[Hawaiiysr]

that bearing is part of the 89 update. 87 didnt have it. if you are doing a full clutch rebuild may i suggest a Neil clutch mod. Since you will be ordering parts you might as well order a few more to have a great operating clutch

[The norm]

89 was the only year that the clutch had the thrust washer. The 89 clutch will work in 85-89 engines if you have all the parts.

[croat1]

The actuator arm upper bearing is discontinued from Honda.  Here’s the info for a replacement:

https://www.forums.trx250r.org/index.php/topic,8405.msg74925.html#msg74925

Joe

[Banshee330]

Thanks guys for all the information,  the actuator arm bearing came with the bottom end bearing kit. The Neil clutch mod will be doable researching it. The counter balance gear was scribed, pressed off fairly easy. Installed new bearing put shaft in freezer and heated gear in a rod box. Mic’ed the bore and the shaft, got about .001” clearance and tried to install. I stuck it twice today. Will try again tomorrow. Cleaned cylinder up with a ball hone, hand some rust spots. Got lots of parts coming in, but still need to order more.

[Banshee330]

Purchased kicker shaft off eBay, doesn’t look like shaft from motor. Seller said it was shaft for 86-87 TRX 250r. Has good splines not sure if it will work. Longer shaft removed from motor, shorter shaft purchased off eBay.

[4WHLr]

The shaft on the left is for 88-89, that mates with the wider gear and the thicker clutch cover.

The shaft on the right is for the thinner gear + the collar, and the deeper cut clutch cover which is for 85-87

Unfortunately the online parts diagrams don't visually show the detail for the 88-89 shaft and gear

[Banshee330]

I am guessing that alot of these parts interchange between cases? Is it safe to say that the serial number on the motor has 87 in the end is a 1987 motor, but other components will work? So if I use the shaft on the right I will have to change other components ? Gears, clutch covers, collars?  Gonna get a manual this week.

[4WHLr]

I would say if you're just replacing that shaft because of the splines being worn, just get the correct shaft.
 After 30 years many motors have different year variations of parts in them. 
To answer your question, if you want to use the shaft on the right that you just bought,  you would need to change the clutch cover, gears, collars, and thrust washers to complete the 85-87 parts package.

A few areas off the top of my head that this can happen is the transmission gearing 5-6,      kicker assemblies, shaft,gear, and cover,      cranks/pistons,   
  water pump shaft/impellers,     and clutch rods/ bearings/and pressure plates.   

  They will interchange through the years, only if you use all the matching parts that coincide with that group of parts. This would make a great post to the tech section if there isn't one already.
I cant say if the Honda manual shows these differences or not. 

You can year class those kicker shafts visually  by the length of the area that the gear rides on them= Just below the snap ring in your pictures.
   
Left in your pic with the longer bearing surface below the snap ring 87-88

Right side in your pic with the shorter bearing surface below the snap ring 85-87

[Banshee330]

Getting there, buying parts and checking stuff!

[broken1]

Looks like a Starrett mic. You & me are at about the same place in our engine builds, only difference being I started mine last August.lol...  I work very slow.

[Banshee330]

I checked the cylinder bore today, it was 2.657 and the piston was 2.654, piston end gap was .014” and .016”.  Reading the manual, I guess it’s been bored.060 over? So what cc is that equivalent too? Like 265?  Everything seems to be ok. Checked transmission shafts and bushings seems all in tolerances. There is a lot of stuff to check!

[The norm]

Stock 66mm is 2.598" so you are at 2.657 which is 67.49mm. That brings you to 258cc. To get a 265cc you need a 68.5mm bore at the stock 72mm stroke. 1mm is .03937"
Loren

[Banshee330]

Hi guys, getting close to getting the motor together. I am not sure if I am missing a part
Or not on my build. The kicker spindle’s shown above I am going to try
The one that came out of the quad. Left spindle. Is there another collar that goes on the spindle shaft? Or is there a collar that is in the clutch cover. On parts schematic it shows item 9 spacer collar. I can’t seem to find this part unless it looks like it may be in the clutch cover? Any suggestions?

[4WHLr]

That #9 collar is used on the earlier 85-87 shafts.
They use the same picture for the 88-89 setup which is what you are trying to use. You will notice that its not listed under the part numbers necessary on the 88-89 schematic, but shown in the pic.
Your cover should have that space taken up partially by the thicker cover, and the thicker gear.
So no spacer needed on yours