94 CR 250 Ground Up Restoration IMS Wide Ratio Transmission Issue

[Moto7man]

Progress on the Rekluse Basket

I had to press out the "starter gear" from the stock clutch basket. I used a spacer from my motion pro suspension tool and the old pressure plate(turned around) locked in my vice to push out the gear. it was tight but it came out without a problem. The Rekluse instructions specified heating the new Rekluse basket in an oven at 400 degrees for 15 minutes, and freezing the "starter gear", then push the "starter gear" into the Rekluse basket. I used insulated gloves from the kitchen, placed the basket on a piece of wood for support on the garage floor. I expected the bearing install into the Rekluse basket to be a pain, but the "starter gear" dropped right in without a problem.

Then I drilled out the rivets on the old basket to remove the stock ring gear. Note the grooves on the old stock basket, yikes.

 

[Zrt1200]

Thanks for posting the Rekluse video link. Thats pretty cool. Glad to see you got your correct carb and things are coming together.

 

[Moto7man]

Yes, things are coming together a little faster now.

 

[Neil E.]

Nice work. I didn't see anything about solving the gearbox assembly. Did you get it sorted out?

 

[Moto7man]

Nice work. I didn't see anything about solving the gearbox assembly. Did you get it sorted out?

Thanks very much! I have got someone helping with it right now. I should have a definite answer within 30 days, then I will post an update.

 

[Zrt1200]

Thanks very much! I have got someone helping with it right now. I should have a definite answer within 30 days, then I will post an update.

Good to here as I was wondering about the tranny as well.

 

[Moto7man]

Here is the updated Rekluse Clutch Basket with the CR starter gear and ring gear installed. The bolts were torqued into place using red locktite then peened with a punch.


New Wossner "B" piston came in the mail today. Piston included wrist pin, clips and rings.

 

[Zrt1200]

Nice Job on the clutch basket. I see you got some new tools to go with that piston as well. You must have took the wife out for dinner.

 

[Moto7man]

Nice Job on the clutch basket. I see you got some new tools to go with that piston as well. You must have took the wife out for dinner.

Lol, yes it is kinda like that. I had a head gasket start to go bad on the little woman's Subaru so I am replacing the head gaskets and doing some preventive maintenance, that's why I purchased the new tools.

 

[Moto7man]

Wide Ratio Transmission Ready for Installation

I want to thank GasGasXC and the IMS guys for all their assistance. Their help was crucial in getting the transmission ready for the installation.

The problem was a typographical error on the older IMS instructions. This resulted in gears C1 and C3 being in the wrong positions. Once the positions were swapped on the counter shaft everything went together perfectly.



It is crucial that you follow the newer instructions on the right page for the countershaft.

 

[Moto7man]

Wide Ratio Transmission Ready for Installation

A few more pictures. Engine build to start ASAP.

 

[Moto7man]

Engine Build Started

New shift case.

New brake side case.

 

[Moto7man]

The cases fit together really well, no machining needed.


New Honda Oem crank,straight from the box.

Wide Ratio IMS transmission

 

[Moto7man]

Parts stacked next to workbench waiting for install. Dan,the penguin isn't for sale.

I used a puller tool to move the crank into the case half. I used two tire irons wrapped in cardboard to rest the tool against the case half. It worked really well. The IMS Wide transmission dropped right in without a problem. Note:The stock transmission has two 23 tooth gears, one on the the countershaft and one on the main shaft, the gear on the mainshaft is a little wider, if you reverse them, the transmission will bind when you install the other case half, this was per Dogger 315 on another site. I measured my two gears, which are IMS gears which are a different size than oem and I made sure that the wider gear was on the mainshaft.

The cases came with all the bearings installed except one of the transmission shift drum bearing. I don't want to use the old one so I have to order one tomorrow.

 

[Moto7man]

The last 96 CR NOS Cylinder in North America.


New head still in the Honda bag.

This is a "B" cylinder so I bought a Wossner "B" piston.

New piston in the barrel.
Misc power valve parts. I replaced the round cover and o ring along with the lever mechanism and head bolt. I ordered a new circlip.


I used this moly for the PV assembly.

 

[Moto7man]

Barrel assembled just waiting on a circlip and new cylinder studs.

 

[Zrt1200]

Glad to see you are making some headway. Keep the pics coming. I was looking at the pic with the piston in the cylinder and noticed the bottom of the exhaust port looks like it does not have a chamfer on the port edge??? Are the ports chamfered??

 

[Moto7man]

Glad to see you are making some headway. Keep the pics coming. I was looking at the pic with the piston in the cylinder and noticed the bottom of the exhaust port looks like it does not have a chamfer on the port edge??? Are the ports chamfered??

Thanks! I ordered some more parts today. I'll look at the cylinder when I get home. I want to complete the build in two weeks then it is time to ride!

 

[Zrt1200]

Thanks! I ordered some more parts today. I'll look at the cylinder when I get home. I want to complete the build in two weeks then it is time to ride!

2 weeks sound like a good time frame to break in a new bike. Check all the ports top & bottom for a chamfer as you dont want to be scuffing up a new piston or catching a ring in that bad boy.

 

[gasgasxc]

I told you!!!!!