Vintage Dirt Bike Q & A

I have all my parts to rebuild my CR250R Elsinore engine. When I plit the case I have 3 parts from the trans that I am not entirely sure where they go. THey sorta jumped out. Everything else I have laid out exactly how it goes back together. If anyone has a diagram they could scan and e-mail to me I'd ppreciate it. mailto:cdnews@comcast.net. If anyone can send it to me I'll put it on my website for everyone to reference. Let me know. Thanks!

Go to bikebandit.com.

I am transmissionally challenged. A little trick I picked up when I split my cases is to have two pieces of aluminum tape about 24" long nearby and a big ziploc bag. When I carefully pull the gear clusters, I wrap the aluminum tape around them, spacers, washers and all, then place in the bag until ready to reassemble.
Of course it doesn't always work without something falling off, bouncing on the concrete and quickly rolling underneath something in the farthest reaches of the garage, but it works most of the time.

...large rubber bands work too.

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Michael Stiles
1979 Honda CR250R Elsinore | 2006 Husqvarna SM510R | 2007 Service Honda CR500R-AF

http://www.cmsnl.com/honda-cr250r-elsinore-1979-us_model7322/partslist/

...beats buying your own parts book.

_________________
Michael Stiles
1979 Honda CR250R Elsinore | 2006 Husqvarna SM510R | 2007 Service Honda CR500R-AF

I got the bike back together but the clutch doesn't release. It seemed to work when I worked the level manually on the bench. There was a lot of slack in the cable when I got it in the frame again. Any thoughts?

Did you put the clutch actuator rod back in??

Yes the rod is in and the "cup" that poushes on the outside part of the clutch that turns the input shaft of transmission is there. There is a black splined washer that is fairly thick that I'm not 100% on where it goes. By the diagrams I'm looking at it has to go begind the inner clutch basket

http://www.cmsnl.com/honda-cr250r-elsin ... E++04.html

In that diagram the washer is #14 and I ahve it placed there currently. It is a splined washer but sits behind the splined area on teh trans input shaft and is slightly loose on the shaft. Is this how it should sit? Seems kinda odd to me, but if it were to sit in the splined area tehre's no way that clutch pushrod could push far enough to release.

So with the clutch assembled as shown in the picture I have to adjust the cable WAY out to get it to release. The two nuts on the lower adjustment part of the cable... Only the nut towards the front is on the cable. To get it to release I have to back the toehr one all the way off and let it hang loose. Seems like something is not right. Before going through the engine it was backed out pretty far but both nuts were securely holding the cable to the lower adjustment mount.

I tried assembling without that splined washer that seems a little loose on the shaft (#14) and the clutch would release fine but not apply all teh way. Some sort of spacer/thrust washer needs to be there to hold the inner basket (#4) close enough to the pressure plate (#6) to engage the clutch fully. I'm 99% sure this is the washer that came from that position as it only seemed to fit there when pulling it apart, and I had it set aside with the clutch stuff.

This is my first time taking apart one of these engines so I could be mistaken, but doubtful as I tried to lay things out in the way they came apart. Any thoughts?

Hmm, All I can tell you is to lean the bike over (if you have trans oil in) and make sure that all the washers, bearings etc. are in place behind and in front of the inner clutch per the drawing and that they are all the correct part.. ie measure them with a caliper (Example washer description says 12X36) and make sure they are all sliding down on the shaft correctly.. Then put the rod in without the outer clutch on and make sure it moves out when you pull the clutch. Make sure part #6 fits on part #4 correctly (the teeth mesh) take #6 back off and put the plates back in and check the operation. I have a 78 and had the same problem, I just basically took it apart and put back carefully as I descibed and it worked. Good luck!