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  • We can rebuild him.

    G'day DBWers.

    I'm in the process of rebuilding the top end of my CRF250X.

    The bike has done approximately 6000kms and I'm changing out the second piston on it.

    Right hand intake valve is just out of spec, so shimming will take place. Intakes are stainless steel and have been in there for about 2500kms. Only been shimmed once previously. After a call to Disco, he assured me that they won't need replacing any time really soon!

    Anyways, I'm putting a new JE piston in (after a good ol' fashioned honing from my newly acquired Flex Hone)

    I checked the piston that came out, and after around 2000kms or so, it's still in spec no worries but I'm replacing it.

    The bore is clearly glazed, particularly at the front and back sections. Cross-hatching is still very evident and there's no bad damage to the bore at all.

    I checked the bottom end play by checking for vertical slack in the conrod - tight as a fish's ********. Sweet.

    JUNE 2012 EDIT: NOT ANYMORE!!!!

    As some know, I haven't ridden my Honda since the Otways Bogans earlier this year and have had back surgery. Anyways, I'm seven weeks post op now, feeling pretty good I suppose, still got some pains and what not but hey that's life.. I decided to start my bike a few days ago to warm up the oil for an oil change. Took it out for a few quick monos and shit, dropped the oil and found a lovely collection of copper shavings in there and some in my oil filter. Time to rebuild the bottom end. I've never done this before but I'm keen to do it. I'll try and document as much as I can in this thread as a source of information for others.

    Obvioulsy the first three pages relate to a top-end rebuild so the rest will continue afterwards.


    Here's some pics.

    Good ol' TDC.



    Woops, it broke and the pumpertron fell out of the valveinator!



    Typical wear on pumpertron.



    Looks like Talla's been busy in here with his hatchett, cross-hatchetting is nice and clear but will be cleaned up with light honing.



    I like pink. Not the singer.



    New JE pumpertron kit.



    Valve clearances and shim sizes just for records and to work out new shim sizes.

    Thanks for just being human.

    Top/bottom end rebuild thread CRF250X.. Click here.

  • #2
    Always like reading a good rebuild thread . . :grinning-
    Time and tide . .

    Comment


    • #3
      Originally posted by pk View Post
      Always like reading a good rebuild thread . . :grinning-
      What about this one?
      "I know I was born. And I know that I'll die.


      The in between is mine"


      ~Eddie Vedder

      Comment


      • #4
        Originally posted by TonyH View Post
        What about this one?
        yeth, this one pacifically - now it's ophicial tho neeee !
        Time and tide . .

        Comment


        • #5
          Originally posted by TonyH View Post
          What about this one?
          Get *@#&*@#&*@#&*@#&ed *@#&*@#&*@#&*@#&.
          Thanks for just being human.

          Top/bottom end rebuild thread CRF250X.. Click here.

          Comment


          • #6
            I forgot to mention my sponsor in this rebuild: beer.



            And some promo for FORCE. Legends.
            Thanks for just being human.

            Top/bottom end rebuild thread CRF250X.. Click here.

            Comment


            • #7
              Good read and pics mate, thanks.

              Does the new JE piston have that black teflon type coating on the skirt?
              I had a 2strk piston coated once (and a ceramic coating on the crown) and the piston came out looking nearly new at the next rebuild.


              Good luck (not that you'll need it) and keep the updates coming.
              Pete.
              '02 TL1000R.'04 450 EXC. '05 KX250F'16 200 EXC.

              Don't like a post or thread? Click on this icon in the top right of the post.

              The opposite of success isn't failure, it's 'giving up'.

              Comment


              • #8
                The JE is indeed a non stick frypan made out of 2618 alloy which is 2% silicon.
                I've got a wossner 4032 sitting here which i think is 11%. Silicon.
                So I guess Kracka's weiner will be stronger but move around more in his hole..

                This is my stocker after 70 hours



                Here's a used version of kracka's JE piston after it had a bit of a hard life - only 83 hours,
                but it did a ride with no coolant.



                These were my valves after 0.40 mm of shimming (basically zero'd out 4 times). Stainless. 190 hours i think.

                Last edited by disco; 22-10-2011, 03:56 PM.

                Comment


                • #9
                  what's the inlet side of your piston look like kracker ?

                  Comment


                  • #10
                    Nice writeup krackas! How many hours are you putting on a piston?

                    I see you stuffed the crank tunnel with a pair of your old panties
                    Last edited by yam-man; 22-10-2011, 08:39 PM.
                    08 KTM 300

                    07 YZ250

                    Comment


                    • #11
                      Originally posted by Disco View Post
                      what's the inlet side of your piston look like kracker ?
                      Like this:





                      Originally posted by yam-man View Post
                      Nice writeup krackas! How many hours are you putting on a piston?

                      I see you stuffed the crank tunnel with a pair of your old panties
                      Roughly around 30 hours I think. That's an OEM Honda piston though, I'm hoping to get around 200 hours out of this JE.

                      I wouldn't waste panties on dirt bike rags. I export them to Japan, soiled.

                      Update:

                      The pumpertron is in. I *@#&*@#&*@#&*@#&ing hate piston pin clips! It's still one of those rebuild moves I'm far from mastering! It took me about 10 attempts to get the right hand side one in, once the piston is attached to the conrod. Putting the left one in is a piece of cake because you can do it while you're holding the piston in your hand. It's a different story when the *@#&*@#&*@#&*@#&er is attached to the conrod and you've got this moving setup which you're trying to put a springy piston clip into. Boooooiiiiiiiiiinnnnnggg!!! "Where the *@#&*@#&*@#&*@#& did that go?? Oh, hooray, it went down the tiniest little gap where my panties rag doesn't quite close everything. Faaaaaark! Where's the magnet? Where's me faaarken beer?"

                      Anyways, fortunately I now have concrete on my garage floor. So, when the clip goes flying through the air I don't have to use a shovel to find it! I used to run my extremely profitable rebuild business (I am the only customer) out of a 2x2 garden shed with a dirt floor. Now, due to business expansion (meth amphetamine lab) I've gone and built this:



                      Oh yeah, before I put the pumpertron in, I checked the ring gap and it was .309. All good there! And, I honed the jug. That was an experience.

                      Why do things on video always make shit look so easy?? On the video, there's no mention that as soon as the whole hone gets into the jug you should up the revs because the flex hone is gonna load up something chronic and you don't want it to bog. So, yeah, my first attempt at honing was successful but I think the above point I've mentioned is very important.

                      Here's the cylinder after honing:



                      Pumpertron in:





                      Anyone who's done this rebuild before will notice a mistake I've made in the two pics above. Nothing fatal, just stupid and forgetful!
                      Who knows what it is??
                      Thanks for just being human.

                      Top/bottom end rebuild thread CRF250X.. Click here.

                      Comment


                      • #12
                        Dunno ?

                        DId you take the shock out ? I Just undo the top sub frame bolt and push down which pulls the carb back from the head far enough to get the cylinder off ?

                        Comment


                        • #13
                          Originally posted by Krackers View Post
                          Like this:







                          Roughly around 30 hours I think. That's an OEM Honda piston though, I'm hoping to get around 200 hours out of this JE.

                          I wouldn't waste panties on dirt bike rags. I export them to Japan, soiled.

                          Update:

                          The pumpertron is in. I *@#&*@#&*@#&*@#&ing hate piston pin clips! It's still one of those rebuild moves I'm far from mastering! It took me about 10 attempts to get the right hand side one in, once the piston is attached to the conrod. Putting the left one in is a piece of cake because you can do it while you're holding the piston in your hand. It's a different story when the *@#&*@#&*@#&*@#&er is attached to the conrod and you've got this moving setup which you're trying to put a springy piston clip into. Boooooiiiiiiiiiinnnnnggg!!! "Where the *@#&*@#&*@#&*@#& did that go?? Oh, hooray, it went down the tiniest little gap where my panties rag doesn't quite close everything. Faaaaaark! Where's the magnet? Where's me faaarken beer?"

                          Anyways, fortunately I now have concrete on my garage floor. So, when the clip goes flying through the air I don't have to use a shovel to find it! I used to run my extremely profitable rebuild business (I am the only customer) out of a 2x2 garden shed with a dirt floor. Now, due to business expansion (meth amphetamine lab) I've gone and built this:



                          Oh yeah, before I put the pumpertron in, I checked the ring gap and it was .309. All good there! And, I honed the jug. That was an experience.

                          Why do things on video always make shit look so easy?? On the video, there's no mention that as soon as the whole hone gets into the jug you should up the revs because the flex hone is gonna load up something chronic and you don't want it to bog. So, yeah, my first attempt at honing was successful but I think the above point I've mentioned is very important.

                          Here's the cylinder after honing:



                          Pumpertron in:





                          Anyone who's done this rebuild before will notice a mistake I've made in the two pics above. Nothing fatal, just stupid and forgetful!
                          Who knows what it is??

                          Didn't put the cam chain guide in?
                          Eat sleep ride repeat.

                          Comment


                          • #14
                            Originally posted by rideorberidden View Post
                            Didn't put the cam chain guide in?


                            Well spotted.
                            Thanks for just being human.

                            Top/bottom end rebuild thread CRF250X.. Click here.

                            Comment


                            • #15
                              Originally posted by Disco View Post
                              DId you take the shock out ?
                              Yes, I did. And, the forks. Off to Chad's tomorrow for a service. The right leg is weeping ever so slightly and I doubt if the suspension has ever been serviced so I'm gonna spend the $300 (just so I can get some stickers on my forks that say Chads). At least they're close too, they've moved into North Geelong now.
                              It'll be interesting to see if it all works better after a service.. Also, they can set my sag, I've never even done it and I gotta say, my bike feels tall. Hope they don't go tellin' me I need a different spring etc etc.

                              Going in for dialysis:



                              Would you bother about this?



                              I wouldn't. ^lol

                              While I was in the shed today I thought I'd get rid of this *@#&*@#&*@#&*@#&er of the front of my bike:



                              And replace it with this:



                              I've gotta say, the Pirelli MXMS was a great tyre but I won't use it again. Too fragile for my pocket. Amazing grip and handling but the side knobs get blown off in the wind!

                              Bike is still in bits! I've gotta get some shims for the valves and as I don't have a shim kit, I'll be giving young Keggles the supermodel a ring.
                              Thanks for just being human.

                              Top/bottom end rebuild thread CRF250X.. Click here.

                              Comment

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