split 250r case assembly

[200x_Basket]

i got a 250r engine in a box and thought it would be cool to take step by step pics of the assembley. I used cr500 crank bearings because the have 8 balls per bearing. any year cr500 bearing will fit. the tranny was assembled so i wont cover that.
a manual is a big help but if you are careful it is not really necessary.

[200x_Basket]

install the bearing in the right case half. to so this freeze the bearing over night and then heat the case in the bearing area with a propane torch unil it is about 240* or so. this will swell the case and shrink the bearing.

DO NOT HAMMER THE BEARING IN!! if it wont slide in, take it to any shop with a press to have it fitted.

[200x_Basket]

now install the right seal. oil it up and oil the case where it fits. GET IT STRAIGHT

it should set about 5mm into the case and not protrude in to the beaing oil hole.

[200x_Basket]

on the inner side it should be flush with the lip.

[200x_Basket]

install the left bearing the same way as before. do not hit the rubber with the torch. you can heat the whole case in the oven at 230 for an hour.

[200x_Basket]

now install the crank. have it in the freezer for 24 hours to shrink it. you may have to heat the bearings with that torch again. slip it together quickly with the gasket because you have to do both sides.

[200x_Basket]

slide the left case on.

[200x_Basket]

install the case screws. be sure to loctite the bolts behind the stator. if they vibrate loose you are in for a LARGE repair bill.

[200x_Basket]

after you torque all the case bolts down install the right seal. set it flush and install the metal crank seal thing?? i do not know what to call it.

[200x_Basket]

install the counter balancer holder on the left side and then the balancer into the case.

[200x_Basket]

now install the counter balancer crank gear. match the dot on the inner ring of the gear with the dot on the crank. then matcht the outer dot on the gear with the dot ont he counter balancer. slip it all on.

[200x_Basket]

now slide on the other crank gear and bolt it all up. be sure the washer is on the correct way. it is marked out.

[200x_Basket]

now assemble the kick shaft. line the dots up.

[200x_Basket]

install the return spring and the retainer

[200x_Basket]

put the return spring and the clip on

[200x_Basket]

install the kicker and twist it clockwise, install the holder.

[200x_Basket]

install the gear and spacer

[200x_Basket]

line the shift drum mark so it is straight up.

[200x_Basket]

now assemble this thing????

[200x_Basket]

other side.

[200x_Basket]

bolt the assembly to the case, notice the position.

[200x_Basket]

install the bushing.

[200x_Basket]

assemble the shifter shaft.

[200x_Basket]

slide the shifter into place. if it is hard to get in then the shaft is bent. REPLACE IT

[200x_Basket]

slide the collar on the clutch shaft. be sure to oil this and ALL the contact parts during assemble. (should have said that sooner)

[200x_Basket]

slide the bearings in

[200x_Basket]

slip the inner clutch gear on over the bearings

[200x_Basket]

slip the clutch basket on

[200x_Basket]

replace the actuator seal

[200x_Basket]

install the actuator. notice the position of the spring

[200x_Basket]

basket in place

[200x_Basket]

install that big washer

[200x_Basket]

slide in the clutch basket

[200x_Basket]

put on the washer

[200x_Basket]

put the nut locker :shocked: on

[200x_Basket]

install the nut and torque it. DO NOT USE A SCREW DRIVER TO HOLD THE CENTER HUB STILL. YOU WILL BREAK THE BASKET. I like to use a gloved hand to hold the center and then hit the nut with a impact gun. I know that i do not get the correct torque but it is enough.

after you tighten the nut bend the locking tab into place.

[200x_Basket]

install the clutch plates. start with a fiber and go fiber - metal - fiber - metal - fiber until it is full. you will end on a fiber.

[200x_Basket]

2

[200x_Basket]

install the clutch actuator rod/ball/cap.

[200x_Basket]

place the ball bearing in the cap/

[200x_Basket]

slide the cap in

[200x_Basket]

install the pressure plate and the springs.

[200x_Basket]

DAMN!! well all that is left is putting the gaset and cover on. in the mean time i will be drilling this out and trying to ez it out :rolleyes:

i hope you enjoyed tonights backyard mechanic :D

[200x_Basket]

got it out in about two minutes!!! :D

[trike250cc]

to much time on your hands :doh: :lmao: good info though :shrug:

[Glenn]

Originally posted by trike250cc
to much time on your hands :doh: :lmao: good info though :shrug:

Not really. You save some major coin doing in yourself. Plus, you know the job was done right.

[liquedfire440]

lets see the finished product

[yamaman]

some people so cheeky after the time he has took to put this info up for everyone!!

to much time on your hands

:doh:

Cool thread Basket:headbang:

[ADW3]

:hail: basket! way to go Chris, threads like this are what sets this site apart (head and shoulders above) from others out there. keep up the good work and, yea, lets see some of the finished product! :thumbsup:

[85Atc350x]

To TRIKE 250CC, he doesnt have too much time on his hands. He is a very patient and helpful person by posting all of this. He probly just saved 50-100 people some money and aggrevation by posting that. Just because your 13 and you parents probly pay for your stuff doesnt mean you should rag on a guy trying to help us out. Good Job 200x basket!!

[200x_Basket]

the topend is soon to come.

i dont think trike250cc was being to bad in me, he did make a :lmao:

[250RNUT]

Excellent job! That info will help me out a bunch

[250rAL]

Basket, I plan on taking my right case cover off to replace the kicker shaft seal and inspect the 20 year old clutch. It's never been off. Can I plan on twisting off any of the bolts? I hate the fact that they put long skinny steel bolts into aluminum. They always want to seize together.

[200x_Basket]

i dont think you have to remove the cover to change the seal

[Blazerone22 350x]

Nice post:headbang: Thanks for taking the time. I'm just searching the site for tips, snapped off one of the water pump cover bolts. drilled it and then snapped off the extractor.

[Black Sheep]

there is one thing mentioned in this post I would like to address.

I would not recomend heating the case with a propane torch and definatly would not recomend heating just the bearing area.

doing this method can cause the case to warp.

the propane torch is not going to be consistant because when you heat one area the other area is cooling.

a better way to heat the case is to stick it in an oven at 450 degrees for about 10 minutes. this way the whole case is heated at the same time and exact temerature

[250rAL]

Originally posted by 200x_Basket
i dont think you have to remove the cover to change the seal

You're right; it popped out very easily.

[Xowner]

basket how did you keep all you bolts seprated were you knew were what bolts went and what?

[Red Rider]

Whenever I'm doing a major disassembly, I always draw a quick diagram, of the piece being disassembled, on a piece of cardboard. Then I punch small holes in the cardboard diagram at the various bolt hole locations, and finally push the bolts into the appropriate diagram holes as I remove them from the piece being disassembled. A little extra work at first, but it sure saves time later on when it goes back together smooth & without the stress of trying to figure out which bolts go where.

[Adam250sx]

Wow excellent post, thanks for the great info! :thumbsup:

[LEMEZING]

thank you for the info!!!!!