Honda Hpp questions....Cylinder loaded

sandman768
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sandman768
Edited Date/Time 11/3/2018 3:50pm
Working on a 1989 CR 250, stripping the cylinder for replate. Have everything out accept the exhaust valve guides....manual states they should just slide out....they don't...any tricks? I have it soaking in pb blaster for the time being. Photo for attention....of course the last stud broke off in the cylinder....


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pete24
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pete24 9/19/2018 5:49pm
9/19/2018 5:49pm
if your sending it to milineium just explain and they will get it out at a reasonable cost
sandman768
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sandman768 9/19/2018 6:32pm
9/19/2018 6:32pm
pete24 wrote:
if your sending it to milineium just explain and they will get it out at a reasonable cost
Thanks Pete, I got them out by lightly tapping on them with a plastic punch...they were just carboned up in the cylinder, I don't think they have ever been removed...bike had stock piston in it...I"ll be posting again when it comes time to setup the powervalves ....Looks a little confusing...
pete24
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pete24 9/20/2018 6:49am
9/20/2018 6:49am
the powervalves are wicked confusing i can do them if im rite there but put up piks if you have trouble and maybe i can help
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sandman768
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sandman768 9/20/2018 12:41pm
9/20/2018 12:41pm
pete24 wrote:
the powervalves are wicked confusing i can do them if im rite there but put up piks if you have trouble and maybe i can help
Thanks Pete, it will be a while, sending the cylinder out soon for replate. I should have bottom end done by the time the cylinder is back. I will post photos if I can't figure it out.

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JMX247
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JMX247 9/20/2018 2:13pm
9/20/2018 2:13pm
the exhaust valve guides have tiny alignment pins that slide into grooves made in the cylinder. The manual is correct, the guides just slide out but the alignment pins mixed with carbon gunk probably made it slightly difficult to remove those things
CD
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CD 9/21/2018 9:15am
9/21/2018 9:15am
Pete, I'm in the same boat as Sandman, got a basket case 87 with the valves frozen so have no reference on how to put them back together. Here's a couple of pics on my first attempt. Set the levers to the position in the first photo with the e clip against the valve block. When I install the spindle arm and drop in into the rack the arms align the slots on the arms aren't aligned like the manual. They also lock at the end of the travel and have to be moved somewhat to unlock. Any suggestions? If you need additional photos I can provide. Thanks





sandman768
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sandman768 9/21/2018 12:37pm
9/21/2018 12:37pm
CD wrote:
Pete, I'm in the same boat as Sandman, got a basket case 87 with the valves frozen so have no reference on how to put them...
Pete, I'm in the same boat as Sandman, got a basket case 87 with the valves frozen so have no reference on how to put them back together. Here's a couple of pics on my first attempt. Set the levers to the position in the first photo with the e clip against the valve block. When I install the spindle arm and drop in into the rack the arms align the slots on the arms aren't aligned like the manual. They also lock at the end of the travel and have to be moved somewhat to unlock. Any suggestions? If you need additional photos I can provide. Thanks





If you are on fbook you can join ... Vintage Honda cr two strokes up to 1999... In the files section, there is a factory manual posted & an Eric Gorr article about the valves...I would post a link if I knew how.....it will still leave you confused, but it's better than nothing...
CD
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CD 9/21/2018 1:17pm
9/21/2018 1:17pm
Thanks, lots of good info there including the entire service manual. Give it a shot this weekend.
pete24
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pete24 9/21/2018 6:23pm
9/21/2018 6:23pm
i always had trouble with them then i had one ported from PC they sent instructions on how to time power valves we start with them pulled out and i think try to guess where the acuator would end up and drop it in do that a couple times and it will work, call PC i bet they have the instructions on file until i did it that way if i got them rite is was cuz i got lucky
sandman768
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sandman768 11/2/2018 10:38am
11/2/2018 10:38am
After a few hrs of playing with these valves I think I have the cylinder setup correctly.
As per Eric Gorr, the left slotted screw is at 11oclock & the right is at 1 o'clock. A functional test of pushing & pulling on the rack, opens & closes the valves correctly.
sandman768
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sandman768 11/2/2018 10:42am
11/2/2018 10:42am
This is how the rack/ acuator rod looks with cylinder upside down.
sandman768
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sandman768 11/2/2018 10:48am
11/2/2018 10:48am
I was unclear how the cylinder rod engaged the rod that protrudes from the cases, it appears the slotted cut out sits on top of the case actuator rod. I will read the manual one more time to see where the case rod should be oriented during cylinder install. I will do a dry run without the piston first...if something looks wrong...feel free to chime in....
sandman768
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sandman768 11/2/2018 5:34pm
11/2/2018 5:34pm Edited Date/Time 11/2/2018 5:36pm
I think I have it figured out...just need to turn the rt side actuator rod to engage the lower rod, then the cylinder sits down flush, then engage the lower rod by turning the clutch cover slotted screw clockwise..the functional test is to turn the rt power valve with the screwdriver and feel the slight resistance of the spring...if no resistance the valve is not engaged. Pretty confident I have it correct, so I installed the top end. We"ll see if it's right when I fire it up soon...
pete24
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pete24 11/3/2018 3:30pm
11/3/2018 3:30pm
been a long time but id say you got it
sandman768
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sandman768 11/3/2018 3:50pm
11/3/2018 3:50pm
pete24 wrote:
been a long time but id say you got it
Thanks Pete, I"ll find out soon enough, should be ready to fire it up in a few days, waiting on a couple small items...

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