Today I went over to GarlicGregg's house and we took a look into my Engine.

He started by showing me the hole through the spark plug hole.

First we pulled for the exhaust and we found a hand full of metal here is a pic of what came out:



Next we pulled the upper part of the Engine off to reveal the piston. Here are some shots of that:







So I am obviously going to be doing a complete rebuild. Gregg and I are going to send our uppers out together to Hoser for our bore work. There is metal pieces everywhere! I am actually looking forward to doing the project since I have never built an Engine before.

My first set of questions:

1) How do I remove this:


2) How do I remove this:


I guess these are my only obsticles preventing me to splitting the Engine.

I'm assuming this is a 250.. Or am I wrong?

More importantly, what in the hell happened to the piston???

Man I bet that ody hauled for aboout 30 sec. that's one big hole.

I don't believe I've seen a burn through quite that large! That sucker's huge!

Did you guys try to find the cause before you tore it apart? Leakdown test?

Unless you already know what caused your piston melt down, make sure you do a thorough check of the fuel system before you fire it up after the rebuild. It definitely went lean which is what caused your melt down.

Rand

Leakdown determined that there was a big tear on the underside of the intake boot.

In the famous words of every mechanic ......... Well there's your problem!

Rand

How does the rest of it look?

Gregg said that everything looks ok. I just need to know what tools I need to pull off the clutch and which one i need to remove the electronics side so I can split the Engine. Then it's cleaning time!

Thumb through the manual you will see the clutch puller and the mag puller, you can get the flywheel puller at almost any Honda shop for about 15 bux I think its motion pro that makes them, they also fit the FL350 flywheel puller so maybe a friend with a 350 can loan you theirs? I forget what you need to pull the stock clutch on a 250 when not using the Honda puller one of the other resident 250 gurus can probably help you, OldmanOdy, OdyStable others? I think Randy at http://www.pilotodyssey.com/PO/viewtopic.php?f=2&t=16721 sells a puller too.

Hoser,

By the way, I told Brandon that you have the capability to do the bore. I think he assumed that it was a foregone conclusion that you would.

Are you busy? Do you have time to do a FL250 for Brandon and a FL350 for me?

Pretty Please?

Thanks
Greg

Denis Kirk http://denniskirk.com, Rocky Mtn, RICKY STATOR, all sell them for like 20 bucks plus tax.

motion pro makes a clutch puller as well I think it was around $20-$30. I can loan you both if you don't want to invest in a set yourself. Just pay shipping, for $5 I can put them both in one of those small flat rate priority mail boxes. get them off then mail them back the next day. You will need an air(or electric) impact gun to get the clutch off easily.

Will the comet 94C clutch puller work on the stock FL350? I have one of those.

I only have FL350s and ATC250Rs. I've never worked on the FL250 before and Barandon did not have his manual with him, so I did not want to try pulling the stuff without the proper tools and the manual.

Greg

the fl350 and 250r should have the same flywheel puller, the clutch puller im pretty sure is different. but I don't have a 94c puller to compare. if it threads into the clutch I don't see why it wouldn't work

Thank you Hotrodd. I really want to buy them cause I have a buddy with a couple 250s that need the same thing.

I called Rocky Mountain http://rockymountainatv.com and they were no help!

Does anyone have links to the tools I need?

I looked on oddysalvage and there was no paypal button next to the tools going to call him tomorrow!

hoser mentioned a mag puller?? Is that another tool I need?

Sorry, NO you need a clutch puller and a flywheel puller, most of all you NEED TO READ THAT MANUAL ASAP!

OK ordered the tools.

Going on a road trip today. Guess I should have some time to review the manual. Taking my Lightning to have the Engine rebuilt. Guess it was a bad month for me and my engines!

wow that is one nasty hole. It brings me back to being a teenager too. First motor (( Internal Combustion Engine ? )) I ever tore down was a fl250. All I can say is take good care of the nut/threads that hold the recoil puller and teeth in place. Mine stripped out and the teeth came out and ended up killing the stator, no fun.

So I just got my puller tools in and I got to work.

I got the flywheel off but no one said there would be a snap sound when it comes loose. I thought that I broke something! LOL

I am having troubles getting the three screws loose so that I can remove the stator.

I moved on to the drive pulley and once again I could not break that loose either!

I am getting fustrated!

maybe an impact screwdriver? on the stator

I always use an impact screwdriver on the stator, once its out I put anti-seize on the threads and you wont have any problems taking it off ever again. make sure you use the right screwdriver on the screws I think its a #3. on the clutch put anti seize on the threads of the puller and use a impact gun on it. it will pop off. I also spray penetrating oil on the backside( on crank) of the clutch the day before. since you are doing a rebuild I would recommend the cr250 cylinder conversion. if your doing all that work you might as well get more power out of it as well

Of course no stores around here carry them! FUDGE!!!

I'm pretty sure Harbor Freight tools in Salinas has them.

What is the CR250 conversion?

Gregg I am off to Salinas tomorrow! Get that impact driver and some sockets for the impact wrench! I did not know there was a difference.