Gen 4 250x Conversion street legal/super moto

other · Post by **other** » March 6th, 2012, 10:55 pm

Jeff4510 wrote:I got it all figured out, Jeff at SH really really took care of me! Blinkers/lights here I come

You did well, I got nothing from them ! S/H harness doesn't have provision for blinkers, did you get a wiring diagram for this ? If so, I'd really like a copy of that . . . . . ?

Jeff4510 · Post by **Jeff4510** » March 8th, 2012, 12:39 pm

Wow, got to Ride around a bit yesterday and was easy on it since its new. Went to start it today and it completely shatter both right side covers from kick starting. Assuming it was the big compression. Is shattering these cases rare?? Not looking forward to pulling it all apart again after 15 minutes on it:([/youtube]

Jeff4510 · Post by **Jeff4510** » March 8th, 2012, 2:16 pm

Post by **MojoScojo** » March 8th, 2012, 2:57 pm

Relatively common failure. Well, maybe not common, but not rare.

Post by **AlisoBob** » March 8th, 2012, 3:39 pm

Yup.....

Jeff4510 · Post by **Jeff4510** » March 8th, 2012, 3:45 pm

MojoScojo wrote:Relatively common failure. Well, maybe not common, but not rare.

too much compression or do the cases just get weak over time?

Post by **AlisoBob** » March 8th, 2012, 3:53 pm

It seems like 90% of the time its right after being rebuilt.

Jeff4510 · Post by **Jeff4510** » March 8th, 2012, 4:01 pm

thanks for the help guys!. anyone have any RH cases for sale?

Jeff4510 · Post by **Jeff4510** » March 17th, 2012, 11:25 am

So I found a motor and am in the process of replacing the cases. Has anyone welded up another support bracket by the kickstart gear? Thinking of doing this

Jeff4510 wrote:

Post by **AlisoBob** » March 17th, 2012, 12:03 pm

I wouldnt weld the cases.... if you want insurance against this happening again... get a decomp setup installed.

gregrobo · Post by **gregrobo** » March 17th, 2012, 6:39 pm

I had 1 very near fatality like that and 1 450x do something very similar check the kick start release tab that is bolted to the center case it cost like $2 bucks and if it breaks it sends the kicker into a forward direction under full engine power into the clutch case and the result is busted cases like your photo

Jeff4510 · Post by **Jeff4510** » March 19th, 2012, 11:16 am

So before I broke the cases I noticed I sometimes had some decent "kcikback" fron the kickstart. I am just curious, how many of you guys experience this? I am running the electrical from service honda so I am seeing if this is a timing issue potentially

Jeff4510 · Post by **Jeff4510** » March 19th, 2012, 11:18 am

other wrote:
Jeff4510 wrote:I got it all figured out, Jeff at SH really really took care of me! Blinkers/lights here I come
You did well, I got nothing from them ! S/H harness doesn't have provision for blinkers, did you get a wiring diagram for this ? If so, I'd really like a copy of that . . . . . ?

sorry, just saw this. No wiring diagram including blinkers but it's pretty simple. Just splice off of the dc power to a blinker relay then a switch then out to the blinkers. I made the entire harness myself and it took a long time mostly due to measuring and soldering like 30 connections

2strokeforever · Post by **2strokeforever** » March 19th, 2012, 5:00 pm

It seems like 90% of the time its right after being rebuilt.

id put money on the splines not being lined up properly....

Post by **MojoScojo** » March 19th, 2012, 5:20 pm

2strokeforever wrote:
It seems like 90% of the time its right after being rebuilt.
id put money on the splines not being lined up properly....

Um... what?

NightBiker07 · Post by **NightBiker07** » March 19th, 2012, 6:01 pm

That right there is the main reason I got the decomp setup....after claiming one kick lever already, I figure it will save me money and headache.

Jeff4510 · Post by **Jeff4510** » March 19th, 2012, 6:16 pm

2strokeforever wrote:
It seems like 90% of the time its right after being rebuilt.
id put money on the splines not being lined up properly....

There is only one way to line up the splines... I've done some calling around and this seems to happen to modified motors. I took out both cases on the right side and I'm thinking it was due to the "kick back". Wish I could tell how it actually broke..

Jeff4510 · Post by **Jeff4510** » March 20th, 2012, 9:06 pm

So it after close inspection it looks like the cases broke from the downforce not the kickback. I say this by looking at which way they actually cracked. I am going to design some gussets to support the kickstart ear on the case so this doesn't happen again. I'll post some pics when they're done

cryzsurfer · Post by **cryzsurfer** » March 21st, 2012, 5:32 am

Mine did that on the second ride and it was completely fresh. I've since found another inner case and got the bearings and seals. Going to put it back together but not sure what I'm going to put the motor in. When it shattered it just bummed me the hell out so I put a spare modded 01 YZ250 motor in the chassis and it's pretty cool but no Hoon that's for sure. It still gets a lot of double takes. Found the aluminum chamber on eBay.
Craigus

Jeff4510 · Post by **Jeff4510** » March 22nd, 2012, 9:44 am

Here's the clutch cover brace almost done. You can see where it cracked on the case

Post by **AlisoBob** » March 22nd, 2012, 9:45 am

This for real????

Jeff4510 · Post by **Jeff4510** » March 22nd, 2012, 9:49 am

you should see the back of the ear, nasty. The back brace will be a gusset type about 5 times the size of the stock gusset. I don;t want this to happen again. it also seems this is one of the weak parts of the design as it is an "ear" just hanging out in space with little support.

Rhino89523 · Post by **Rhino89523** » March 22nd, 2012, 10:05 am

No offense, but if you are going to take the time to weld this all up and make gussets and everything why use a piece of metal that looks like it's been clawed by a very angry pair of vise grips. I believe Roosty has made this repair before and gussetted as well.

hoofarted · Post by **hoofarted** » March 23rd, 2012, 8:50 am

AlisoBob wrote:This for real????

Post by **AlisoBob** » March 23rd, 2012, 8:54 am

BannedCR500Riders.com

Gen 4 250x Conversion street legal/super moto

broken cases

Re: broken cases

kickback?

Gen 4 250x Conversion street legal/super moto

case support