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-   -   94 CR 250 Ground Up Restoration IMS Wide Ratio Transmission Issue (http://www.gasgasrider.org/forum/showthread.php?t=22310)

Moto7man 01-22-2017 11:55 AM

94 CR 250 Ground Up Restoration IMS Wide Ratio Transmission Issue
 
I have been working on this restoration for about 18 months gathering parts. I am in mid assembly and I ran into a problem with installing the IMS Wide Ratio Transmission. I have a thread on another forum and some of the GG members already know about it. I have 4 of the 5 IMS gears installed without any problems at all. (2 on the mainshaft and 3 on the countershaft). The problem is the last C3 gear on the countershaft fits perfectly but the I.D. of the gear (with the bushing) is too big for the shaft. Any suggestions would be greatly appreciated.


This is the countershaft,the bigger gear is the stock Honda gear and the other gear is the IMS gear. Note the stock Honda bushing(collar)inside the IMS gear. Between C3 and C5 it is a bushing that rides inside C3, there are also a single washer on each side of C3. There isn't a spacer. The I.D of replacement gear is 24.98. The bushing(collar) O.D is 21.99 and the Bushing(collar) I.D is 18.99.I have attached photos showing the replacement gear loosely positioned on C5 without any collar so you could see the gap between gear and countershaft. I also included photos of C3 and C5 which show witness marks that they were previously mounted together. C3 and C5 seem to fit together perfectly except for the bushing(collar).

Moto7man 01-22-2017 12:01 PM

photos to be reposted.

Moto7man 01-22-2017 03:44 PM

This what she looked like when I picked her up about 18 months ago.

http://i.imgur.com/8UYKuOL.jpg

http://i1185.photobucket.com/albums/...shextp9cn.jpeg

http://i1185.photobucket.com/albums/...psuandjiaq.jpg

Moto7man 01-22-2017 03:52 PM

And this is what she looks like now,

Moto7man 01-22-2017 03:56 PM

And the garage beer fridge

john r b 01-22-2017 04:40 PM

Very nice work , super clean. what about the tank?

gasgasman 01-22-2017 05:21 PM

Nice project.
Be sure to grind the paint off the frame at the motor mounts.

Neil E. 01-22-2017 06:07 PM

Does the large bore of the suspect gear fit on any other shaft steps? If it's not supposed to go somewhere else, maybe the wrong gear was put in the kit.

If all else looks correct (except for the bore), a machine shop could do up a bronze bushing to press into the gear. Aluminum bronze would be tough enough to survive.

Moto7man 01-22-2017 10:03 PM

Quote:

Originally Posted by Neil E. (Post 174231)
Does the large bore of the suspect gear fit on any other shaft steps? If it's not supposed to go somewhere else, maybe the wrong gear was put in the kit.

If all else looks correct (except for the bore), a machine shop could do up a bronze bushing to press into the gear. Aluminum bronze would be tough enough to survive.

I am having someone else who is intricately familiar with these IMS kits verify the gear was the correct one for the kit. I sent him all the dimensions today. Thanks for the aluminum bronze specification, I was vaguely thinking about someone like that but Neil I could not articulate it with your precision.THANK YOU!:D

Moto7man 01-22-2017 10:07 PM

Quote:

Originally Posted by john r b (Post 174228)
Very nice work , super clean. what about the tank?

Thank you. I purchased a 3.1 gallon IMS natural tank from Chapmoto that should be shipped on 2-15.


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