CRM250AR Rebuild

[mekros]

Knowing how some mechanics work/think, I'm not surprised at all if the spacer was recycled and used again.

[mekros]

Life has been busy outside of the bike world, over the weekend I managed to break out the heat gun and blind bearing puller:









Bagged and tagged as usual











Aluminium spacers will have to be made for this now that I have dimensions.


Parts have been ordered from Honda and are awaiting arrival from Japan. I found it was cheapest to buy from a local dealer, the overseas prices were pretty much on par with the locals before you factor in postage!


The common bearings are the only ones I need to order now.



I forgot my linkage bearings so I'll give them another shot when I get out there again.

[mekros]

Does anyone know if the all balls linkage bearing kit will be compatible for the AR?

[mekros]

No reply to my question above so I ordered Honda "collars" and generic bearings...

Whilst I was waiting for bits to come in:

My second child was born, now that means even less time to tinker and ride

A set of Sun branded XR400 motard rims were bought at a cheap price from a guy that decided to part out his bike.


I've been playing around with what can restore colour to faded plastics:



I learnt that Honda did a swifty with the headstem bearings so you have to be on your toes when ordering the generic part.

When the parts arrived, a local workshop was kind enough to let me use the press so the linkage and headstem bearings are back on, the path to reassembly has begun.

[mekros]

I got a chance to work on the bike a fair bit and bearings were pressed in or fitted

Fitting the lower steering race was interesting.


motard wheels test fitted.


I have three front brake calipers and all of them have different problems so none of them are optimal. I need to rebuild one set. The clearance between the caliper and the rim means it is an outright pain trying to take them on and off, I’ll have to have a motard set up and a dirt set up.

[knackeredMk1]

I had a set of pads for on road and one for off road. I used the thinner, part worn set for the motard setup as they were easier to fit due to the size of the disk.

[mekros]

Yeah the thickness of the rotor means I usually leave one pad out, fit the caliper and then slip the pad back in.

Did you also find that the clearance from the caliper to the rim is bugger all?

[knackeredMk1]

Yes. Main reason for the thinner pads as I could get the calliper on without messing about.

[mekros]

ok, progress has seriously slowed down with an increase in responsibility at work and two children really do suck up all free time.

I've managed to source some electrical connectors, snap the head off the rear brake bleed nipple after flushing the fluid (drained it by undoing the brake line banjo bolt initially), and some other trouble with the front brake.

[ElectroMotor]

Hello My Friend

Im From Cali Colombia and i have a CRM250 1998 but i dont know .. but i think i have an AR Active Radical System.
What do you think ?
http://hondacrm250.blogspot.com/
Thanks.

i Found now, i have a Version MK1 CRM250Rk/k2 (1989-90)

Thanks my Friend


Hey Good Job

[knackeredMk1]

Take it from me Alex (and I have slightly revised my first opinion) you do not have a 1998 AR. From the pictures you have shared the engine from your CRM is Mk2 (1991-1993) or possibly a Mk1 missing the PV controller. There are a whole heap of extra parts and parts that are different from the ones you show that the AR has. The frame is probably Mk1 with a CR shock fitted. The Mk1 (1989-1991) has conventional front forks as you have and the Mk2 has USD forks and it is quite difficult to refit conventional forks onto a USD bike. Are the stations on your bike 41mm?

The shock is not a standard CRM fit. All the plastics are Mk1 or Mk2 (these are the same and very different to the Mk3 and AR)

[mekros]

8 months of progress and no posting....shame on me.



I managed to slowly chip away at things, replaced the the brake caliper with the snapped bleed nipple, threw away my good speedo cable (that was a moment in stupidity), crimp new connectors onto the electrical plugs that were stuffed and assemble it into what resembled a working bike.



A CR250 was sourced (the last of the steel framed beasts) and I'm comparing them side by side to see what of the CR I can use on the CRM for cheaper parts.



A few more months in between.



Fresh fuel into the tank and into reserve mode.....she smokes! All the indicators are on??? None of them flash? More head shaking and laughing at the irony and delay to registration.



I then have to move (again), this time to the foot of some local mountains where I'll get to enjoy some twisty riding and the bike is now waiting for a mate to bring around a power supply so I can do some electrical fault finding.