1986 Helix CN250 
Another Helix

In March of 2009  I picked up a scruffy 1986 Helix and decided it was time to start another page to document  my progress on rejuvenating it.  It's in need of a lot of love with almost 50,000 km as it was used year round in all weather as a commuter.  It currently doesn't run due to "electrical problems" . The body panels were replaced after an accident with chinese panels which suffered badly in a subsequent accident (both low speed spills). As well as doing a "down to frame" restoration, I'm hoping to use the remains of the chinese body panels to build a custom body with more storage, better streamlining and wider footrests. 

First some pics of the scooter the day it was delivered and then some pics of  the various stages of stripping it down.
86 Helix
Honda Helix Frame

So far it looks like it'll need the following new parts;

Shock absorber bushings
Oil filter screen
New front brake Rotor
New front brake pads
brake caliper rebuilding kit
new tires
new springs for stands (side and kick)
instrument cover (plastic scratched as usual)
new seat cover

I haven't inspected the drive components but I have spares for the Helix including new fuel pump, new regulator, new clutch pads and a couple of good used belts as well as two spare carburetors and a used muffler.

I also have a couple of spare "parts motors"  that can be used  to replace any non-moving parts. I prefer to replace moving parts with new.  Aside from the Chinese body parts shown I also have some original body parts and spares.

There is the usual surface rust that accumulates on a scooter driven year round. None of it is so bad that it can't be removed with wire wheel, sandpaper etc. The most important part is to remove all the parts to make sure they're clean and well sanded in even the non-visible parts. Once I've sanded, cleaned and painted each part it can be re-assembled. The paint will be black enamel as it's good at preventing abrasion and has good weather resistance. Theres a lot of nooks and crannies to get at.

The engine has good compression  but  it has issues.  I came into possession of it because it had "electrical problems" (no spark) that couldn't be easily diagnosed by the shop. Everything tests OK according to the service manual but there was no spark at the plug. The next step would have been tearing apart the motor and replacing  the alternator and pulse generator which would have been very expensive with no guarantee of results. Take a look at the picture of the scooter at the top again and you can see how both the owner  and shop concluded pouring money and time into it with no guaranteed results was not a sensible option.

After a lot of cleaning of the engine and case, I removed the rh crankcase cover . There was a small metal tab shaped in a 90 degree bend that was loose at the bottom of the crankcase. Nothing visible to show where it came from.  The flywheel had damage on the tab that triggers the ignition pulse. It was like a crater with an indent and then a ridge around the crater  that stuck up considerably.  The pulse generator "nub" doesn't appear to have any damage but because the pulse generator is mounted on the cover, it's not easy to measure if  the distance between flywheel tab and pulse generator  is increased. The damage could possibly prevent a pulse from signalling the cdi/ICM to send  current to the ingnition coil.  

Honda Helix cn250 flywheel
I could repair the damage to the tab and then adjust the pulse generator mounting bolts to decrease the distance to see if that produces a spark. It would be a trial and error process. I've decided to wait till I can afford a flywheel puller (more expensive than the others in my collection) as I'll eventually have to pull the flywheel to see if I can locate where the broke metal tab came from originally. Might as well check out everything (like oil pump clearance) as well as I'm exploring and theres lots of other clean-up work to keep me busy in the meantime.

Because there's a lot of panel damage , I'm going to see if I can make some modifications while repairing the panels.  On my First Helix I always thought there should be more room in the trunk for helmets and other light gear you might want to store after riding to a destination.  I also thought my size 12 feet needed more room and that moving the rear brake control to the handlebars would give me more foot room and a more comfortable riding position with my 6'3" frame.  The Graphic below shows some of the design changes I'd like to make.
Custom cn250 Helix

TO BE CONTINUED......
Helix Links
Lonnies Honda Helix site Craig Vetters Streamliner Helix Helix Discussion Forum Yahoo Honda CN250 Group
Yahoo Honda helix discussion group Honda Helix modified for shorter riders Owners and service manuals Honda OEM Jacks Scooter Shop General info
Japanese Fusion Club
Cheap Custom Helix site (Japanese) Fusion Style (Japanese)

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