Putting things in places they ought not to be (250R Hybrid Motor build)

[Billy Golightly]

I ended up advancing the timing a bit more this afternoon and got it to clean up pretty good and was running AWESOME, took it for a spin and was whacking on it pretty good when it started to make some noise. Think I souped the transmission...

I am gonna pull the clutch cover off and take a look, but something definitely didn't sound right from that area. Maybe later this evening or tomorrow, we will see.

[Thorpe]

That sucks! Hope it's something minor!

[Billy Golightly]

I pulled the clutch cover last night. Found quite a bit of fine metal, some medium pieces but mostly fines. The basket nut had worked itself loose. I had reused the nut lock (I knew better really but ignored reason in this case) and it had started to back off. It looks like it came into contact with the kicker gear as it was wobbling around. I did also notice though even after tightening it down that it still was pretty damn loose. I have found even "good" ones have some play, but this seemed like it could still wobble around into the kicker gear tightened down. I had replaced the 2 little needle bearings but not the bushing they rode on.

Turns out the bushing (28242-HA2-010) is discontinued, so I might make a new one out of some brass or something. I have a suspicion it is worn down is part of my problem. I ordered 2 new needle bearings again, and also a new pancake bearing for the pressure plate (89 style). Aaand 4 of those nut locks just so I have spares for the future

I did run the trans through all the gears with the clutch off and everything in there seemed to turn and move smoothly, so I'm I'm 99% sure that is the noise I heard and I'm hoping thats where the metal came from also, was it bumping and getting into the face of the kicker gear.

[oscarmayer]

that sucks man. what about the metal in the piston area that was on the plug?

[Billy Golightly]

I ran it some more in the shop and did not discover any other material on the plug, so that is when I decided to take it for the test ride and heard the trans noise.

Not saying its "fixed" but I ran it in the shop for 15 minutes before going out for a ride and didn't find anything on the plug or in the pipe

[08rap]

At least thats all it was. I know it sucks but it could of been worse!

[onformula1]

I pulled the clutch cover last night. Found quite a bit of fine metal, some medium pieces but mostly fines. The basket nut had worked itself loose. I had reused the nut lock (I knew better really but ignored reason in this case) and it had started to back off. It looks like it came into contact with the kicker gear as it was wobbling around. I did also notice though even after tightening it down that it still was pretty damn loose. I have found even "good" ones have some play, but this seemed like it could still wobble around into the kicker gear tightened down. I had replaced the 2 little needle bearings but not the bushing they rode on.

Turns out the bushing (28242-HA2-010) is discontinued, so I might make a new one out of some brass or something. I have a suspicion it is worn down is part of my problem. I ordered 2 new needle bearings again, and also a new pancake bearing for the pressure plate (89 style). Aaand 4 of those nut locks just so I have spares for the future

I did run the trans through all the gears with the clutch off and everything in there seemed to turn and move smoothly, so I'm I'm 99% sure that is the noise I heard and I'm hoping thats where the metal came from also, was it bumping and getting into the face of the kicker gear.

Check out Bronze Light Bushing Material-

http://www.nationalbronze.com/oil-im...d-bearings.php

[MTS]

I can't seem to find the page I downloaded service manuals from for my sleds and I no longer have the computer that has those files.

Hopefully MTS sees this and can verify those numbers for you.

Yes that is correct .138", 3.36mm for the 800

[Billy Golightly]

Okay cool. Well the bushing the needle bearings ride on is out of stock everywhere, so I guess I'm gonna wait till my new needle bearings get here, take some measurements of the one I have, see if I can't tighten things up a little bit with a new one and go from there.

[Billy Golightly]

Well after getting my needle bearings and replacing that stuff in the clutch, tightening it all back up, I cranked it up and ran it. Still had some noise....


So I pulled the pipe and plug again and found an aluminum slurry in the combustion chamber. Don't know what. Almost looks like it had coolant mixed with it somehow. So, obviously, gotta pull it and tear it back down, see what I find.

[RIDE-RED 250r]

Awe man!!!!

[Billy Golightly]

I'm hoping this was just caused by a type new bearing.

[yaegerb]

ooooooo....is that an exploded counterbalancer bearing?

[oscarmayer]

dang billy. that totally suck man. i feel for ya.

[Billy Golightly]

ooooooo....is that an exploded counterbalancer bearing?

Yes. Brand new aftermarket with about an hours run time total on it.