If you think that this repair sucks now, just wait to see what you think when you are done. If your clutch does not completely disengage when you try to pull the lever in, it usually means that your clutch plates are still in good shape. Until the a machine is warmed up, the clutches are usually very grabby. You should make sure not to use anything metal to tap on the cylinder and cases when you try to split them. I use the rubber handle on a hammer because I don't have a rubber mallet. Just be cautious and take your time, you'll get it apart. If you get frustrated and start bashing on stuff you will just end up costing yourself more money. I would recommend getting new dowels for your cylinder and cases, they cost less than 5 bucks total and the old ones usually need replacement. Honda P/N 94301-10160 for the cases, 2 required, about a buck a piece. Honda P/N 94301-12200 for the cylinder, 2 required, about a buck a piece. Also you should make sure that the mechanical seal and bearing for the water pump impeller shaft are in good condition. They are located in the right hand side cover that you have already removed. If these go bad you will likely be looking at a severely damaging engine siezure. Make sure you have a torque wrench when you put this back together. Be careful to arrange all of your parts in some kind of container, especially the transmission and clutch parts. I use Ziploc freezer bags for this. The '85's have an update for the clutch that solves some problems if your's doesn't already have it, and there is a fix for the slipping kickstarter that you likely have also. If you call the guys at calatv.com they can help you out with any parts that you might need at a reasonable price.

 

LOL, let me clear up something. I went on a "rampage" with my chain because it has needed to be replaced since my uncle bought it 2 years ago, but I could never get myself to buy a new one unless the old one broke(or got cut in half[img]i/expressions/face-icon-small-smile.gif[/img]). I'm replacing everything on this thats wore out right now, instead of doing one thing at a time. Oh and when I was asking about paddles, I'm selling mine because chances are I'll never make it to the dunes until next year, so theres no point in me having them when the money could go to pay for repairs.

 

I would imagine you know this, but you should replace the chain if it is heavily worn. If you break the chain while riding the machine, chances are the stock "case saver" will not do the job, it's pretty weak. When the chain breaks it swings through the front sprocket at high speed and smashes into your engine case, if it hits it hard enough it will break it, and you'll enjoy what you're doing now all over again plus the cost of case repair/replacement. The case half will run you $250 new with the appropriate bearings plus the time and gaskets. Pretty expensive compared to a chain.

 

Does anyone know what size that big nut is on the (?)clutch hub(?)
Is that what that thing is called?

 

Itracerx, go to service honda's web site:
http://www.servicehonda.com/HARD%20P...mes%20page.htm

On the left side, there are links to different pics of the 250R including motor, tell us which nut you are referring to.

 

I believe the large nut that holds on the clutch basket it a 27mm.
ERIC

 

It's the nut that holds the clutch basket in place. Are you positive it's a 27mm retro? I don't want to have to buy the worng size socket. Oh yea, while we're stil on the subject of motors, some of you are saying to buy a case splitter, but I'm on a budget so if I don't need it, I don't want it. Would using an exacto knife to break the seal on the case halves work, then just pull them apart, or would I damage something?

 

This should help answer your question:
http://www.servicehonda.com/HARD%20P...mes%20page.htm

 

Brian, I went to the Service Honda site and they didn't show a picture of the nut I am refering to, but go there and look at th picture it's the big nut that holds #5 in place.

 

I believe the large nut that holds on the clutch basket it a 27mm.

Yea, I do it all the time.

ERIC