Messages

1

FAQ's, How-To Guides & Useful Information / Re: 1986 TRX250R Dealer set up instructions

« on: January 04, 2024, 09:57:57 PM »

Joe, Thats got to be another unicorn like the 87 atc.
I still have all my old literature, but never noticed that white hood and air dam.
An early prototype picture maybe?
Good eye !

2

The Mad Scientist / Re: Long forgotten R parts

« on: March 07, 2023, 08:13:16 AM »

Powroll Motoforce

I have a clear one on my R now, and had a black one on a past project.

But who did the molding, I don't know...

Correct Bill it’s MotoForce.  Pre Fullbore

Joe

Cool trivia Joe!
 I didn't know of the connection between the two.

3

The Mad Scientist / Re: Long forgotten R parts

« on: February 27, 2023, 01:06:13 PM »

Powroll Motoforce

I have a clear one on my R now, and had a black one on a past project.

But who did the molding, I don't know...

4

Engine and Bottom End / Re: Bearing removal

« on: April 29, 2021, 10:07:02 PM »

Awesome !!!  Thats the perfect time to do a pressure check for peace of mind, and avoiding trouble and headaches after its installed.

Just in case you're not familiar with that you can go to the Duncan racing website and go to the tech center, then technical documents,
two stroke, then two stroke pressure test.  ( wish I had a direct link for you)

5

Engine and Bottom End / Re: cr500 clutch mod/ hard lever pull

« on: April 26, 2021, 09:13:44 PM »

Are you still using the fibers and steels that you got it with?
Double check your thicknesses, and fiber (7), and plate count (6) with the honda manual.
Also double check that actuator arm is letting the rod return as far as it can.
When you have the push rod pulled out and the cable disconnected you can lift that arm up and out and have a look at the rod pocket also while you are there.
I think you said it has the big thrust washer is behind the inner clutch hub, right? #19 on a parts diagram

Check those and let us know, I'm running out of ideas lol

6

Engine and Bottom End / Re: cr500 clutch mod/ hard lever pull

« on: April 26, 2021, 06:51:53 PM »

I have a new in the package Honda 89 update kit here that has all the 1989  clutch throw out parts in it, and the pushrod is maybe a tiny bit over 8"
 (Its still in the packaging)

7

Engine and Bottom End / Re: cr500 clutch mod/ hard lever pull

« on: April 26, 2021, 06:11:12 PM »

It would be in the center of the pressure plate where that stuff would push on it to release it.  The oil will sometimes hold it in there, when they get disassembled.
It looks like it might be there but its a liitle hard to tell.
 Just trying to make sure you dont have mismatched parts, since it was assembled incorrectly for some reason when you got it.

8

Engine and Bottom End / Re: cr500 clutch mod/ hard lever pull

« on: April 26, 2021, 05:23:30 PM »

Can you also post a picture of the clutch lifter? The piece on the end of the clutch rod that the needle bearing goes over.

I see the needle bearing, but is there also a steel washer in the center of the  pressure plate? kind of hard to tell in the pic.

also, is the clutch arm in its correct position, with no cable input?

9

Engine and Bottom End / Re: Bearing removal

« on: April 18, 2021, 02:54:26 PM »

That would be no problem, it should get there with just a stamp. I have three spares so no trouble at all.
I thought I bought a set of the assorted washers from Tony years ago, but I can’t find them.
I appreciate the tool rental also, lol.
I’ll send it off tomorrow

10

Engine and Bottom End / Re: Bearing removal

« on: April 18, 2021, 10:00:44 AM »

Those are some really nice installation tools you made there. That should have kept them from deforming pretty well.
If its not too late I have a few of those washers nip for just in case here, and could throw one in the mail for you for free if you still need one.

11

Engine and Bottom End / Re: Bearing removal

« on: April 18, 2021, 12:07:42 AM »

Thats the right  number for the pressure plate thrust washer. 1 is what is in there stock.
This was a long time ago, but Tony = Pumashine here was going to cut some these washers at various thicknesses to dial in the free play a little tighter. 
That clutch arm should rotate pretty smoothly. Maybe the bearings got seated a little too firmly?

12

Engine and Bottom End / Re: cr500 clutch mod/ hard lever pull

« on: April 14, 2021, 10:22:11 AM »

The old diagrams didn't even show the pressure plate thrust washer in them if i recall, just the bearing.  This setup was for 1989 only
There should be a machined cut out in the pressure plate for the washer to sit in if you have the correct pressure plate, to run that 89 throw out bearing set up.

13

Engine and Bottom End / Re: cr500 clutch mod/ hard lever pull

« on: April 14, 2021, 10:17:38 AM »

Yes, the thrust washer goes between the pressure plate and the bearing so the needle bearings don't ride on the aluminum. 

14

Engine and Bottom End / Re: Bearing removal

« on: April 04, 2021, 12:36:26 PM »

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

15

Engine and Bottom End / Re: Bearing removal

« on: March 24, 2021, 09:29:01 AM »

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