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Old 02-23-2009, 03:16 PM   #16
Olas OP
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Location: Englewood, CO
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Quote:
Originally Posted by Clayjars
I wouldn't use a regular bolt for that application. That puller is most likely hardened so it won't deform under pressure. If you don't want to buy the puller, drop down by the bike shop and have them pull it off for you. It could be cheaper as they have the tool on the shelf.
Point taken, thanks.
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Old 02-23-2009, 03:26 PM   #17
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Need input....

Guys, i'm not sure what to do here. Need some input. The cylinder "looks" to me like it could just be honed and another (new) 76mm piston be fitted. Not too sure though, i'd have to take it to the shop and have them tell me. Though, i'm wondering also if I should just buy a 77mm piston and have them bore it over 1mm. I'm even contemplating buying a new sleeve and starting at 74So, here are my questions:

How big can you go with these stock sleeves? I see you can buy pistons up to 78mm. Is the sleeve prone to any damage being bored out so much? Will I have to modify my gaskets (Moose complete engine kit) to fit a 77mm piston?

So many options to choose from, I may be leaning towards a 77mm piston more than the others though. Thoughts on this?

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Old 02-23-2009, 03:34 PM   #18
johnnyandjebus
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I may not be able to contribute anything useful to the technical knowledge here, but I sure can like a pro!


What he said, looks like a great project!!
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Old 02-23-2009, 06:26 PM   #19
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Getting the ball rolling....

Well, to get the ball rolling, I ordered this:

XRs Only Piston Kit - Honda XR250R - 76.5mm / 10:5.1 / 272cc
COATING: Standard Coating
XRPK-0272$189.951$189.95
K&L Supply Cam / Timing Chains - Honda XR250 (86-95)
KL-120250$79.951$79.95
K&L Supply Flywheel Puller - 22mm X 1.5mm RH Internal - Honda XR250R XR350R XR500R XR600R XR650L
KL-35-5944$20.931$20.93

Once I get the piston, i'll be able to take the barrel to the machine shop. While that's getting done I plan on splitting the cases for some general inspection. Pictures will be comming....

Now, common sense tells me to replace the chain tensioner while i'm in there. I haven't looked at it closely but I looked at the guide and it looked "ok". Whaddaya say?
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Old 02-24-2009, 11:56 PM   #20
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thats gonna be a nice bike! I used that same wiseco in my 250R, you will notice it makes more noise (piston slap) right away but Ive put over 5000 mi on mine since installing it. if the spring in the tensioner is still up to par Id reuse it.
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Old 02-25-2009, 02:39 PM   #21
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Quote:
Originally Posted by apex
thats gonna be a nice bike! I used that same wiseco in my 250R, you will notice it makes more noise (piston slap) right away but Ive put over 5000 mi on mine since installing it. if the spring in the tensioner is still up to par Id reuse it.
I used a wiseco piston in my XT and it does make some noise when cold but goes away once warmed up. I don't think the XR's only kit comes with a wiseco, though. From their desription it says it will either be a JE Piston or Ross Piston.
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Old 02-25-2009, 02:56 PM   #22
smokeeater495
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You mentioned the PO experienced smoking after rebuild. By the look of the piston dome I'm not surprised. That's a LOT of built up burnt oil. The piston skirt is spotless, I don't see any scratches on it. Something caused oil to pour into the cylinder and the top end was starved of oil. The cylinder looks good too. I would get the piston bead blasted or use a brass wire brush to scrape off the goo. Then slip the piston down the bore and take some measurements, ring end gap too. I know you bought a bunch of new parts. If you have time let us know how the old parts measured up.

smokeeater495 screwed with this post 02-25-2009 at 03:02 PM
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Old 02-25-2009, 03:53 PM   #23
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Quote:
Originally Posted by smokeeater495
You mentioned the PO experienced smoking after rebuild. By the look of the piston dome I'm not surprised. That's a LOT of built up burnt oil. The piston skirt is spotless, I don't see any scratches on it. Something caused oil to pour into the cylinder and the top end was starved of oil. The cylinder looks good too. I would get the piston bead blasted or use a brass wire brush to scrape off the goo. Then slip the piston down the bore and take some measurements, ring end gap too. I know you bought a bunch of new parts. If you have time let us know how the old parts measured up.
Yo, smokeeater! I'll definitely measure the old parts when I get a chance! Haven't had much time to mess with this bike since I bought it! I was able to take off the tank, side covers and shock last week and was looking at the general condition of parts. Mostly i've just been ordering parts I will want to replace. Most everything looks good. The frame's a little scratched here and there but that's ok, I'm going to powdercoat it at school before the semester ends.

I ordered all the bottom end bearings today. We'll see how long it takes them to show up. I've been using Service Honda because they have the lowest prices on OEM stuff that i've found anywhere. They beat bike bandit by far! It takes them a little longer to send the parts out but they've done me good so far. I'm assuming most of these internet part stores get their OEM parts from the same manufacturer? Is this correct? Anyone have any recommendations of any other stores for OEM Honda parts?

I lost my camera cable so I havent' been able to upload any pictures...Once I find it i'll get on it, promise!
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Old 02-25-2009, 04:40 PM   #24
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Oh, yeah, forgot to mention that I found an unmodified airbox and a carburetor on Ebay. All for $70 shipped. Not a bad deal if you ask me. Getting closer and closer! I can't wait to start tearing things apart.
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Old 02-25-2009, 04:59 PM   #25
Timeless
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before you go tearing into the bottom end....Possibly the owner messed something up in the top end area that caused the cam/lifters to wear....I dont know about xr's but some of my old bikes had external oil lines to bring oil to the top end...also no valve seals could be an issue..could lose alot of oil and make it smoke....usually when an engine starves of oil, the piston will seize first because that is what has the most heat/friction...and your bore and piston look ok. Another thing.....Even if the bike was completely run out of oil, most lower end bearings, crank included will survive much longer than the piston, etc and usually dont need to be replaced in this situitation....check for freeplay/slop in the crank before u tear into it.
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Old 02-25-2009, 05:06 PM   #26
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Main reason I want to split the cases is because the bike's been sitting like this since the mid 90s and there's a lot of dirt/dust/junk that's fallen in there since. The play/slop in the crank seemed normal to me when I felt it (haven't measured yet). Since i'll be in there cleaning stuff up, i feel like I might as well replace the bearings...
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Old 02-25-2009, 07:56 PM   #27
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Quote:
Originally Posted by Olas Altas
Anyone have any recommendations of any other stores for OEM Honda parts?
Ron Ayers has a good reputation for service and prices, and they have an online parts fiche.
Between them and Service I've been able to find whatever I've looked for.

Any luck getting in touch with Jeff? He could be off riding - he was in Arizona riding with Ned and Scot while my cylinder was being bored. He's really good about getting back in touch when he's around and missed the call.
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Old 02-25-2009, 08:09 PM   #28
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Quote:
Originally Posted by Blakebird
Ron Ayers has a good reputation for service and prices, and they have an online parts fiche.
Between them and Service I've been able to find whatever I've looked for.

Any luck getting in touch with Jeff? He could be off riding - he was in Arizona riding with Ned and Scot while my cylinder was being bored. He's really good about getting back in touch when he's around and missed the call.
Thanks, Blake. I called Jeff yesterday and left a message. Don't want to bother him too much but i'll try again next Monday if I don't hear from by this weekend. I sort of figured he'd be out riding or something since the weather's been fantastic! Since i've heard such good things about him, I'd like to have him inspect my cylinder head and also check out the valves/valve guides. Maybe more...i'll probably bring the whole top end with me and go from there.
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Old 03-04-2009, 05:01 PM   #29
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Numbers

I took some measurements today and curious to see what you guys think... Some parts are at their service limit and some are beyond.





Camshaft
Standard
Service limit
Actual




Intake lobe #1 + #2
29.529mm
29.34mm
#1: 29.154mm

(1.1626in.)
(1.155in.)
(1.162in.)



#2: 29.463mm
(1.160in.)




Exhaust Lobe #1 + #2
29.330mm
29.14mm
#1: 29.032mm

(1.1547in.)
(1.147in.)
(1.143in.)

#2: 29.260mm
(1.152in)




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Old 03-04-2009, 05:02 PM   #30
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Valve Springs







Inner
38.83mm
37.9mm
#1: 37.109mm

(1.529in.)
(1.49in.)
(1.461in.)



#2: 37.185mm



(1.464in.)




Outer
38.30mm
37.1mm
#1: 36.617mm

(1.508in.)
(1.46in.)
(1.481in.)


#2: 37.947mm


(1.494in.)




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