help! Big internal damage!

[Michael Shelgren]

I had a piston come apart in my 2001 CR250. There is some serious
scoring of the cylinder. Is it worth getting the cylinder resleeved or
should I just buy a new one. New is around $240. Also, what is the best
way to get piston fragments out of the bottom end? I hate to have to
split the cases, this bike is almost new! thanks for any help!

Mike
2001 CR250

[Simmonsmc]

You can have the cyl repaired for half the cost of a new one(not sleeved!),
split the case it's not that hard and will ensure you got all the pieces out,
that can stick in the lower rod brng.

Mike Simmons
99 KTM 300 MXC
AMA/ Dist.36
Hayward Honda/Suzuki/Sea-Doo 510-886-0644
D-H Cycles KTM/Suzuki/Cannondale Modesto

[Mark Nelson]

I agree with mike on having it fixed. THere are about 5 places doing it in the
states so you should have no problem getting it done

Mike

You say splitting the cases isn't hard. Do you have the tools? I've had case
splitting tools on back order since Dec 00. I'm getting pissed. K & L Supply
merged with Kent Moore and aren't making anything until some new toolings are
made up. In the mean time I'm waiting.

Anyone have some tools they want to sell? I want the case splitter (3 arm) and
the crank holding tool (Kawi style).

Thanks

Mark Nelson
#567 Oklahoma Cross Country Racing Association
1996 YZ 125
1999 YZ 250
2001 YZ 250F

[Mark Nelson]

Mike Wrote:
>Also, what is the best
>way to get piston fragments out of the bottom end? I hate to have to
>split the cases, this bike is almost new! thanks for any help!

Been there done that!

The best way is to split the cases, however, here is a trick I've used with
sucess.

Pull the engine out of the frame and run a bunch of pre-mix thru it. Pour it in
the top and shake up. Dump it out and repeat until clean pre-mix comes out
(check for metal peices). Rotate the crank around too. This will loosen
anything that might be stuck in the bearings.

[Dennis]

Getting junk out of the bottom end can be done without splitting cases,
but
you take your chances of missing something.

I've done this on 1000cc 4/s bikes and 125cc 2/s

turn it upside down on a frame of some sort so the bad parts can fall out.
get an air powered tool that can spray kerosene like a siphon with a hose.
and spray up into the cases. use a long skinny tube that will fit up in
between flywheel halves and case and soak the living daylights out of the
bottom end. Rotate teh crankcase while working.

If you are lucky, any loose chips will get washed out onto the ground.
I had a FZR1000 where I put all the clutch parts together like a jigsaw
puzzle to make sure I got everything. ( the clutch and crankshaft share the
bottom end and oil)

If it was the end of the riding season, I would agree that splitting cases
is the way to go, but summer just got here so be a real biker and take a
chance.

P.S don't smoke while trying this.

"Mark Nelson" <c5flt...@aol.com> wrote in message
news:20010514235831...@ng-fo1.aol.com...

[Volker Bartheld]

Hi Mark!

On 15 May 2001 03:51:29 GMT, c5flt...@aol.com (Mark Nelson) wrote :
>You say splitting the cases isn't hard.

It definitely isn't. You have to fight your fears, though.

>Do you have the tools?

You just need a flighwheel-puller, a crankcase-puller (that can be built
from a stable piece of metal by drilling two holes of right dia and
distance. You'll see what I mean when you check out your owner's manual)
and a freezer/refrigerator (to have some coold beer and cool down the
crankshaft bearings.

Apart from that, you'll just need a gasket set, hot air gun, standard
tools (ratchet, wrenches and the like),... and: patience.

>I've had case splitting tools on back order since Dec 00.

A flywheel puller is cheap and widely available. Every motorcycle
hardware store should have a matching version for your CR.

>Anyone have some tools they want to sell? I want the case splitter (3 arm) and

That's overkill. You just need pull off the crankcase(bearing) from the
crankshaft. A little heat is gonna help. No big deal! Re-assembly it
merely done by temperature difference. No press needed. Guaranteed.

Contact me at agento at rrr dot de for more info.

Good luck,

Volker

('94 CR250R completely rebuilt in Dec 2000 - Feb 2001)

[Volker Bartheld]

Hi Dennis!

On Tue, 15 May 2001 21:44:18 -0400, "Dennis" <den...@snip.net> wrote :
>If it was the end of the riding season, I would agree that splitting cases
>is the way to go, but summer just got here so be a real biker and take a
>chance.

Well, Dennis you're partly right. Especially on the big bore 4 strokes.
Refitting piston, rings, camshaft and all that stuff is a pain in the
@ss. For a small 2-stroke, I would recommend splitting the cases. You
can never guarantee that every bit flushes out easily. The whole
operation really is no big deal. You waste one weekend but make sure,
that the engine doesn't get stuck when you least need it.

You can also check the gearbox when you're at it.

Greets,
Volker

[Mark Nelson]

>
>Contact me at agento at rrr dot de for more info.
>
>Good luck,
>
>Volker
>
>('94 CR250R completely rebuilt in Dec 2000 - Feb 2001)
>
>
>
>

Volker
Send me an e mail. Mine keep getting kicked back.

Thanks

Mark

[Peter Patton]

People have done the 'fill the case with solvent and rinse it out thing,'
but I would split the cases. Bummer I know. Have the shop look at your
cylinder. It may only need re-nikeling.

Peter

Michael Shelgren wrote:

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