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  #111  
Old 07-23-2017, 01:44 AM
Moto7man Moto7man is offline
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Location: Murfreesboro,Tennessee
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Rekluse EXP,Rekluse Torque Drive Clutch Pack, Boyesen Super Cooler with clutch and ignition covers.



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2011 GG EC 300E, 1994 CR 250R, 1984 RM 250 E, 2022 Ranger 300

"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

"I think best when I have a wrench in my hands." Soichiro Honda

"Dreams are messages from the deep."
-Unknown Sardaukar
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  #112  
Old 07-24-2017, 09:49 AM
Moto7man Moto7man is offline
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The Rekluse kit came with these new steel U wedges that clip into the clutch basket. In the above photo you can see the steel wedges pressed into the new recluse basket. Sorry the pictures are so huge, I am still learning how to post from Imgur.
__________________
2011 GG EC 300E, 1994 CR 250R, 1984 RM 250 E, 2022 Ranger 300

"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

"I think best when I have a wrench in my hands." Soichiro Honda

"Dreams are messages from the deep."
-Unknown Sardaukar

Last edited by Moto7man; 07-24-2017 at 09:51 AM. Reason: Info on photos size
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  #113  
Old 07-24-2017, 10:03 AM
Moto7man Moto7man is offline
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Location: Murfreesboro,Tennessee
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Default Engine Assembly on the Beast.

Honda has specific depth specifications for the crank seals. On this side the seal must be 2mm below the crank case surface so a case splitting tool is used to set the seal depth, Per Dogger315.



This is the cases before the clutch install with the spacer and bearing installed.


New recluse clutch basket.




New washer for the retaining nut.
__________________
2011 GG EC 300E, 1994 CR 250R, 1984 RM 250 E, 2022 Ranger 300

"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

"I think best when I have a wrench in my hands." Soichiro Honda

"Dreams are messages from the deep."
-Unknown Sardaukar
Reply With Quote
  #114  
Old 07-24-2017, 10:15 AM
Moto7man Moto7man is offline
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Join Date: Aug 2011
Location: Murfreesboro,Tennessee
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These are the new Rekluse steel wedges for the clutch basket.



Steel wedges installed in the clutch basket.



New Honda inner clutch and pressure plate.



Clutch holding tool.


Clutch nut torqued to spec.
__________________
2011 GG EC 300E, 1994 CR 250R, 1984 RM 250 E, 2022 Ranger 300

"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

"I think best when I have a wrench in my hands." Soichiro Honda

"Dreams are messages from the deep."
-Unknown Sardaukar
Reply With Quote
  #115  
Old 07-24-2017, 10:25 AM
Moto7man Moto7man is offline
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Join Date: Aug 2011
Location: Murfreesboro,Tennessee
Posts: 2,536
Default Boyesen Super Cooler

Right side case cover and Super Cooler assembly and Boyesen impeller installed. The impeller screwed onto the Honda pump assembly but be careful, the nut cast into the impeller is a std size and not metric, don't ask me why?



Super cooler mounted up. The cooler comes with its own gasket, so the two Honda gaskets with the metal separator plate are not used. Also, the kit comes with a black rubber cover and hose clamp that shut off the stock Honda return line.

__________________
2011 GG EC 300E, 1994 CR 250R, 1984 RM 250 E, 2022 Ranger 300

"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

"I think best when I have a wrench in my hands." Soichiro Honda

"Dreams are messages from the deep."
-Unknown Sardaukar
Reply With Quote
  #116  
Old 07-25-2017, 10:43 PM
Moto7man Moto7man is offline
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Location: Murfreesboro,Tennessee
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Default Power Valve Pinion Cavity Probe to Air Leaks?

I am getting ready to install the top end tomorrow. In the photo above you can see the lower power valve shaft in the corner of the case surrounded by a cavity. I have installed new bushings on each of the pinion shafts for the power valve actuation mechanism. I have read that there can be a air leak through the power valve pinion cavity unless the cavity is packed with moly 60. Is this correct?

Here is a photo from another site with the proposed fix.

__________________
2011 GG EC 300E, 1994 CR 250R, 1984 RM 250 E, 2022 Ranger 300

"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

"I think best when I have a wrench in my hands." Soichiro Honda

"Dreams are messages from the deep."
-Unknown Sardaukar

Last edited by Moto7man; 07-25-2017 at 10:58 PM. Reason: add photo
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  #117  
Old 08-07-2017, 10:53 AM
Moto7man Moto7man is offline
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Default CR 250 Wide Ratio

Ok, I got a lot done this weekend. This is where I started on Friday night.



I used an 18mm Bux Tool to install the circlips in the Wossner B piston. Its takes about 45 seconds per side, this tool is awesome!







The barrel went on without any problems, I set the ring end gap at .4mm.



Per Dogger, I preloaded power valve at .5mm.


I installed a new Honda oem head. I did not have it milled yet because I wanted to see how it runs in the stock configuration.
__________________
2011 GG EC 300E, 1994 CR 250R, 1984 RM 250 E, 2022 Ranger 300

"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

"I think best when I have a wrench in my hands." Soichiro Honda

"Dreams are messages from the deep."
-Unknown Sardaukar
Reply With Quote
  #118  
Old 08-07-2017, 10:59 AM
Moto7man Moto7man is offline
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Location: Murfreesboro,Tennessee
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Head torqued down to Honda specs.



Countershaft installed with cad plated washer and new oem bolt. I used a clutch holder to secure the countershaft as I torqued it down to spec.



Engine ready for install into the frame.

__________________
2011 GG EC 300E, 1994 CR 250R, 1984 RM 250 E, 2022 Ranger 300

"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

"I think best when I have a wrench in my hands." Soichiro Honda

"Dreams are messages from the deep."
-Unknown Sardaukar
Reply With Quote
  #119  
Old 08-07-2017, 11:01 AM
Moto7man Moto7man is offline
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Location: Murfreesboro,Tennessee
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A couple more shots of the motor.



__________________
2011 GG EC 300E, 1994 CR 250R, 1984 RM 250 E, 2022 Ranger 300

"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

"I think best when I have a wrench in my hands." Soichiro Honda

"Dreams are messages from the deep."
-Unknown Sardaukar
Reply With Quote
  #120  
Old 08-07-2017, 11:09 AM
Moto7man Moto7man is offline
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Join Date: Aug 2011
Location: Murfreesboro,Tennessee
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Motor in the frame.





New Honda OEM radiator cap.



YZ450F rear brake pedal fit great but the stock return spring won't clear the case, I need to find an alternative.





__________________
2011 GG EC 300E, 1994 CR 250R, 1984 RM 250 E, 2022 Ranger 300

"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

"I think best when I have a wrench in my hands." Soichiro Honda

"Dreams are messages from the deep."
-Unknown Sardaukar
Reply With Quote
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