Honda CBX 250 Restoration

The left fork starting leaking today



I wasn't planning on getting them rechromed just yet but I guess I'll have to stretch the budget and get it done now before ruining another set of seals.

Still trying to track down the exact seal size but I can't find much information about the different model types eg RS, RSE etc. The seals I've got are 33x46x11 and are for the RSE but the dust covers look different.

From fiche the part number is 51490-KK6-305 but I can't confirm measurements. Will update when I know.

 

Forks are off ready to go to Rad Hard Chrome in Rocklea tomorrow.



Also new clutch kit arrived today.


It has obviously never been replaced before as it took a fair bit of persuasion to get the cover off. Any idea how to remove the central nut without destroying it? The XL350 seems to have a 27mm nut instead of this stupid thing. I can't get the impact gun on to it.

 

I've already tried the flat blade and hammer but can't get it to move. All I'm doing is destroying the crenellations in the nut.

You can see in the centre shaft there is a small cutaway section where the collar of the crenellated (castellated?) nut was punched into it to stop it moving. This broke off as I bent it back out. I can't see anything else stopping it from moving but it won't budge.

I'll sleep on it and try again tomorrow.

 

Cleaning 30 year old gasket off is not a fun job. The good part is that I can confirm that it has never been opened before and is very clean inside. Nothing in the filter screen at all apart from a couple of pieces of grass?



I also decided to have a look at the small weep from the oil drain plug that has been annoying me since I got the bike. I started poking the threads with a screwdriver and a couple of them fell off! Looks like the plug has been super tightened at some point and stripped the thread. What's the best way to fix this? Helicoil?

 

What would you recommend? Helicoil seems to be a lot cheaper.

 

New clutch is in, just waiting for the clutch cover gasket to turn up. I was considering using RTV but decided to do it right the first time and get a proper gasket.

Time-sert kit also arrived, bought it from Cross-Tools who seem to be the (un)official Australian distributor but will order from the US next time and just wait the month. Ended up costing $220 which I suppose is comparable to helicoil if you consider you get 5 inserts in the kit. Anyone have any stripped 12x1.25 threads they need fixed?

One thing I was wondering, you can see in my drain plug photo in previous post, there is a channel cut into the thread which I'm guessing allows all of the oil to drain. When I put the insert in this isn't going to exist anymore. Is this going to be a big problem not being able to drain all the oil?

I also wanted to mention for future reference that the fork seals for the CBX250RSE are different. The CBX250(F) requires fork seals with measurements 30x40.5x10.5. Honda part number is 51490-KK6-305 but a 'generic' seal that fits can be found by searching for part number 33-129-07. Eg. http://www.linkint.com.au/Product/33-129-07_item.html


Lastly not bike related, I gave my RX7 an oil change and took it for a rare drive and had to share a pic.

 

Multiple reasons, mainly because I'm a masochist and learn by doing things the wrong way.

There's also a feeling of achievement about being able to fix every small problem on the bike without anyone else touching it.

 

Not horrible but bad enough to cause one of the seals to leak after riding it daily for a couple of weeks.

 

Yep thanks Risky. The place that I bought the kit from replaced a couple of the standard inserts with a few shorter ones the right size for the oil pan.

 

Update time. Forks have been rechromed and rebuilt and are back on the bike. New front brake pads and clutch were also done during the downtime.

Timesert was also installed on the drain plug but it's still leaking. Not sure what to do at this point.
I think it's leaking between the insert and the new threads where that small cutout is.

If I want to ride this to Sawtell in a couple of weeks I'm going to have to take it in somewhere to get it fixed as I'm moving the weekend before the ride and have car repairs planned for this weekend.