Vic,
Replace them all. Inexpensive for peace of mind.

http://hodakapartsidaho.com/index.php/w ... ms-hodaka/

I think you are looking for scan 6.

Don't have the answer but here is a pic of an 03 crank on the left and a Toad crank on the right.

Pinhole

Can't post picture at the moment. Found a pinhole near the stator mount bolt hole. Try again after it dries.

Pressure test fail. JB Weld to the rescue.

Bob,
It would be if I was the one with the idea. Credit goes to Kelly and Greg, they put a great write-up in issue 2-24. I used an RM unit cause it was handy.

Fitted 1990 RM250 air filter and cage. Mounted Honda cdi unit. Test fit engine. Next is finish up clutch and pressure test.

Closer

Welcome, this is a great group!
Geary in Wa. state.

You're probably going to want to rebuild the crank anyway. A crank mod to use a 97 piston and a rebore may be a more economical route it the end.

It seems like someone with a mill could make these without too much trouble. I found 2.5" x 1" stock on ebay for a dollar an inch cut to length. So about $4 each for the material.

The rubber flange I have is cracked and needs replaced or repaired. No new ones available at this time. So I took one of my 03 ones that was in poor shape and removed all the rubber. Then I filed the holes in a standard Mikuni adapter with 70mm bolt centers so it fit over the studs on the reed cage....

The fenders are about the only pieces on the whole bike that are useable with just a little cleaning.

BTW... In for a penny in for a pound

And no Ed I didn't use my 03 cylinder

Bottom end assembly day!

Pop, great explanation, thank you!
Matt, I'm fat, I need all the grip I can get
I will see if I can get another fiber disc.

I ordered a Kolene clutch kit for my 03 and didn't end up getting it installed. I have another 03 clutch and thought I might use it on my 97. 03 uses 4 fiber and 5 steel, 97 uses 5 fiber and 4 steel. Clutch cage is the same pn for both. Clutch hubs have same dimensions bit 03 has more holes for oil ...

What engine is/was it?

I looked through the parts diagrams for a few different models. Most start with fiber. The 03 is the only one I found where it shows 2 steel plates then fiber, steel, fiber, steel, fiber, steel, fiber. Is there a particular reason for this arrangement?

Al, if you are interested in repairing the newer cases I can send you a broken Toad case and cracked shift cover. You can keep them and use for measuring.
I will even clean them first

Max, search for;
Case repair?

viewtopic.php?f=1&t=2875

Looks like a great start!

Congratulations!
Hope it all comes together. We like pictures

Progress.