79 CR 250 rebuild

I ordered a "big boy" American made Dennis Stubbelfield puller...lost confidence in the puller I have when the wrench would move and the puller didnt...I have a 33mm Stubbelfield for my 72 and it looks unbreakable...wont feel nervous about using a breaker bar if i have to on the Stubblefield.....Lets talk crank pullers now...anyone use the Tusk Crank Puller on a non primary kick bike like my 79?...i know i can stack spacers/sockets but would rather use a proper tool since this is my first time and am trying to avoid screwing up to the point disgust...
thanks
bob

Death From Above before you ask..
Came in 6th in class today in the enduro...8 seconds out of 5th, 2 minutes out of 4th, and 12 minutes out of 3rd...first and second were light years ahead of me in enduro time...

Hey Squid, awesome showing! I have been doing so many things, I have not enjoyed the travel and the thinking that It's about the time you spend on the bike. I will do better. I will pm you about the endure and how to do it.

I have only worked on the 72 450. But the pusher that you need to separate the motor you have I think is available from Halls ask for Bob. He is awesome and knows the fiche.

Got the flywheel off....The Stubblefield puller came in the mail today and with a little extra effort and a small breaker bar it popped off...Ready to split the cases next with the guidance of a friend who owns a local shop.

Hey that motor is missing the flywheel!

Cases are split...they actually came apart pretty easily....Some Mag Rot in the right side case...also found some nasty bits.. cant see where they came from..i don't see anything sheered in the tranny or the clutch...I would think it would be easy to find where it came from since they are pretty big pieces...update shift forks scored...i wonder if the scoring on the one on the far right was from the metal I found?
Bob

Hey Squid, looking good! All opened up, nice. Those marks on your shift fork on the left are strange, can you take a closer pic and of both sides? The 1st and 2nd fork wear look normal but the one on the right is less obvious. The little material/rot missing in the bottom of the right cover is nominal as long as it's not thru to the other side. And I would check the depth. Now those pieces of metal... I can't think of where they lived before they were found, but if I was you, I would check every dog and contact point in the trans and clutch/kick side of the motor. I missed the tell tale sign of a gear popping out, the shift fork being forced out of position and getting too hot in the process, and the dog edges were rounded. Also make sure the fork shafts are straight and the bosses they live in are not out of round. Good luck. I'm getting ready to tune another 450 crank. Also got the generator motor almost complete. Projects!

I saw one on ebay and it looked the same, I'll see if I can post a pic.

yeah...saw that also...the search continues....it really looks like a piece of spring...cylindrical and about the same diameter...only thing i can think of is the PO snapped a spring and replaced it with out getting the pieces out?

When I got the 450 together for the first time, I was running it on the dock outside the shop and all the sudden it stalled and ran and stalled. I restarted it and it stalled again. I took the covers off and found some metal in the teeth of the primary and clutch ring gear after pulling the plug and chain so I could rotate the assembly, I was like WTF. So I picked the metal out and tore the motor down and could not find one thing missing, broken or dented. That motor was brand new clean when assembled. So the moral is... some SOB must have put that in the motor while I wasn't looking, what a dick!! Clean it and reassemble with known good parts and you should be fine.

I'm wondering if the PO snapped the kick start return spring or a shift spring and couldn't find the pieces of the old one..it does look like a piece of spring...couple of mm long and the same diameter

Hey Squid, It looks like it could be a spring part , and if running a race they might have forgotten about a broken part of a spring in the bottom of the case and went on.

The case is apart so all other incidents are null. Make the rest as best as you can and do not wonder. Good luck Squid, after seeing the Combat Wombat I KNOW that will be an awesome machine. I hope to run with you and it!!

Took the CR out for its first ride to verify transmission and clutch operation..Tranny shifted fine through all gears ...clutch engagement is real late almost all of the way out...interesting ride with absolutely NO BRAKES!...now on to the suspension and finally some paint and plastics..


View: https://youtu.be/Z9GJkbbHyH0


bob

bit of work to get those drums working good ahead

Nice Squid, but hey, bikes idling are for sale....Bikes doing brotys are known to increase the endorphins that make men disappear into the setting sun!!


Glad it runs. Great job. Not everyone can bring a bike back to life!!

Almost finished with the rehab.....need new cables, chain and a rear brake plate. The one on it floats in and out and all over the place.. I noticed the bushing was not seated all the way or in straight for that matter...pressed out the bushing and the hole for it on the brake plate was worn over sized. the PO used some thin metal to take up the slack and had silicon all over the outside edge of the plate to i guess help keep mud out because of the poor fit...

can you bore and resleeve it?

Looking good Bob, can't wait for the swap meet. Hope to find some parts I need.

Nice job. I like the front fender... what is it?