New Horse In The Stable

at least I made good use of my down time waiting for my top end. I was able to clean my shop and make a tool to torque my cylinder base nuts.

I also "Hinson" modded my clutch basket and inner clutch boss.


I also realized that the PO wasn't running chain rollers, so...... Made some of those too. Thanks sicivicdude.

harley1-5 said:

that's awesome how do you like the lt250r?

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LOVE IT! Just rode today for a good 2 hours. It's an 87. Has some work done to it. Pulls HARD.

It's all over but the cryin. Motor went together well except for the Achilles heal. I misplaced the damn woodruff key! Went to dealer and scored a new one along with a few extra parts like exhaust springs and some oil.



Today was the big day. I double checks my fluids and she fired up on the third kick. I was surprised that my initial carb setting were spot on. Only had to adjust idle screws a few turns.

I did my 3 idle / off idle heat cycles. Then moved into making a series of three heat cycles and breakin rides. I am impressed with the shift star mod. What a difference that is.

All in all. It seems to be running nice. Tomorrow I will build up some more time on it.

Herpderplol said:

Good eye. the chain is too tight

with the rider on the seat, the chain should have ~40mm of play. or about 1.5 inch

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I thought I measured it correctly. I, being heavier than my wife, layed on seat and checked free play. It was about 1.5 inches. Now is it supposed to be @ 1.5 total or in each direction.

It is a non o-ring chain if that has anything to do with it.

Blaaster said:

40mm overall, with a gentle pull.

Are the chain and sprockets a matched set , or has old been used with new?

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Both sprockets and chain are new. I will double check it tomorrow.

A couple more upgrades came in the mail. My 400ex rear shock arrived. Bushings should be here tomorrow. Put a set of nice 300ex works shocks on the front. Whew. What a difference in ride there. It sits a little lower but still has a good stance. I will try to get a few pictures up later.

dirtysquared said:

I'm sorry I missed this thread till now. Nice work on the Blaster, and that's a very nice LT you have too.

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Thanks! The blaster completes the family of 2 strokes now. Daughter has an LT80 and my young lad has a Predator 90.

Took a few pictures of the ride height as it is setup using 300ex front Works Dual Rate shocks and the 400ex rear shock.





What a difference in ride!

Ok. Found a problem and need some advice.

Yesterday when I was in the garage I noticed a smal (half dollar size) wet spot under the motor. After wiping floor down and underside of motor I found that it is coming from the stator cover. I removed the cover and see that the gasket is really oiled and there is a small collection of oil on the floor of the stator cover. I'm not seeing oil on stator. Maybe a slight film off it.

Trying to isolate where it is coming from, I ruled out the following.
- idle is fine and does not race. No white smoke.
- leak test did not reveal any leaks.
- stator side crank seal is slightly cocked (bad install by me) but was sprayed with soapy water and the crank was rotated slightly during leak test, no leak detected. ***considering this as my only foreseeable eff up during build****
- the oil matches that of crankcase oil (using a 10w-40 ATV transmission oil). The slight sponge is definitely different and I'm running Klotz (oil smear on white paper matching what motor oil looks like)

Now. Where do I go from here?
Could it be leaking from case bolts? Stator screws? Im not sure if that is possible.
Could the crankcase pressure be high if tube is pinched off? (Not seeing oil around shift shaft seal, clutch lever or sprocket)
Stator side cover was damaged side but the repairs I performed along with lapping the cases should have corrected it. Could there be pin holes or cracks I'm not seeing?


Currently I have the stator plate off and sprayed clean and dried. Tomorrow I'm hoping to see the source. Any suggestions would greatly be appreciated!!!

Larry's Shee said:

Test since discovery.

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Yes. Pulled it apart and leak down tested it with the stator plate removed to have a good visual of seal.