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  #1  
Old 01-22-2017, 12:55 PM
Moto7man Moto7man is offline
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Default 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).
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2011 GG EC 300E, 1994 CR 250R and 1984 RM 250 E

"If you stop eating donuts you will live 3 years longer. It's just 3 more years that you want a donut."
―Comedian Lewis Black

Last edited by Moto7man; 07-19-2017 at 11:16 AM. Reason: Spelling
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Old 01-22-2017, 01:01 PM
Moto7man Moto7man is offline
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photos to be reposted.
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2011 GG EC 300E, 1994 CR 250R and 1984 RM 250 E

"If you stop eating donuts you will live 3 years longer. It's just 3 more years that you want a donut."
―Comedian Lewis Black

Last edited by Moto7man; 07-19-2017 at 11:18 AM.
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Old 01-22-2017, 04:44 PM
Moto7man Moto7man is offline
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This what she looked like when I picked her up about 18 months ago.





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2011 GG EC 300E, 1994 CR 250R and 1984 RM 250 E

"If you stop eating donuts you will live 3 years longer. It's just 3 more years that you want a donut."
―Comedian Lewis Black

Last edited by Moto7man; 07-13-2017 at 01:38 PM.
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Old 01-22-2017, 04:52 PM
Moto7man Moto7man is offline
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And this is what she looks like now,
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2011 GG EC 300E, 1994 CR 250R and 1984 RM 250 E

"If you stop eating donuts you will live 3 years longer. It's just 3 more years that you want a donut."
―Comedian Lewis Black

Last edited by Moto7man; 07-19-2017 at 11:18 AM. Reason: Info
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Old 01-22-2017, 04:56 PM
Moto7man Moto7man is offline
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And the garage beer fridge
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2011 GG EC 300E, 1994 CR 250R and 1984 RM 250 E

"If you stop eating donuts you will live 3 years longer. It's just 3 more years that you want a donut."
―Comedian Lewis Black

Last edited by Moto7man; 07-19-2017 at 11:19 AM.
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Old 01-22-2017, 05:40 PM
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john r b john r b is offline
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Very nice work , super clean. what about the tank?
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Old 05-04-2017, 09:21 PM
rvangeel rvangeel is offline
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Sorry to go off topic but this talk of the $399 rekluse has been talked about before. This is the CRF450 part #. Is there any issues with getting the clutch adjusted properly? I remember something about custom washers used as spacers to get the right adjustment?


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Old 05-05-2017, 07:53 AM
Zrt1200 Zrt1200 is offline
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Quote:
Originally Posted by rvangeel View Post
Sorry to go off topic but this talk of the $399 rekluse has been talked about before. This is the CRF450 part #. Is there any issues with getting the clutch adjusted properly? I remember something about custom washers used as spacers to get the right adjustment?


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Thanks. As now I know why when I searched it showed a CRF450. I did a bunch of search's and found all kinds of info on installing the Honda rekluse. A couple washers is easy. But if I needs to use a rekluse clutch basket to make it work smoothly thats another $250. As for using the Honda rekluse. Watch the video.

https://www.youtube.com/watch?v=LsqKrh8fmZk

http://www.gasgasrider.org/forum/showthread.php?t=15126
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Last edited by Zrt1200; 05-05-2017 at 08:50 AM.
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Old 05-05-2017, 08:41 PM
Moto7man Moto7man is offline
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Quote:
Originally Posted by Zrt1200 View Post
Thanks. As now I know why when I searched it showed a CRF450. I did a bunch of search's and found all kinds of info on installing the Honda rekluse. A couple washers is easy. But if I needs to use a rekluse clutch basket to make it work smoothly thats another $250. As for using the Honda rekluse. Watch the video.

https://www.youtube.com/watch?v=LsqKrh8fmZk

http://www.gasgasrider.org/forum/showthread.php?t=15126
As you can tell from the bottom thread, I did a lot of work measuring the Honda Clutchpack and making it work in my Gasser. That same Clutchpack is still in my gasser and it still works perfect. You don't need the Rekluse Basket, the stock one is fine. I only use the Rekluse basket in the my gasser because I am a too picky for my own good. The stock gasser basket squeals a lot but works fine. the Rekluse is very quiet. In my 95 CR 250 My stock basket was "junk" so I had to buy a new basket so I just bought a Rekluse Basket.
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2011 GG EC 300E, 1994 CR 250R and 1984 RM 250 E

"If you stop eating donuts you will live 3 years longer. It's just 3 more years that you want a donut."
―Comedian Lewis Black
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Old 05-06-2017, 08:44 PM
Zrt1200 Zrt1200 is offline
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Quote:
Originally Posted by Moto7man View Post
As you can tell from the bottom thread, I did a lot of work measuring the Honda Clutchpack and making it work in my Gasser. That same Clutchpack is still in my gasser and it still works perfect. You don't need the Rekluse Basket, the stock one is fine. I only use the Rekluse basket in the my gasser because I am a too picky for my own good. The stock gasser basket squeals a lot but works fine. the Rekluse is very quiet. In my 95 CR 250 My stock basket was "junk" so I had to buy a new basket so I just bought a Rekluse Basket.
Thank you for the info.
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