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Our 2019 CRF250R had all six of the small bolts that hold the flywheel and starter gear together loosen/break. Some of the heads backed out and got caught between the stator and flywheel.

New stator, flywheel and bolts on order.

Anyone hear of anyone else experiencing this problem?

Bike has about 50 hours on it with piston changed out about 5 hours ago. Mech says they never even opened up that side of the engine when the piston was changed.

I have not heard of this , but that is not to say it can't happen ..... The first thing I do with a new (or new to me) dirt bike , is basically go over the entire bike , as usually they have just enough grease on the linkage and steering stem , to get the bike thru the dealer ..... but usually the engines are assembled on a automated line and all parts are torqued accordingly before moving down the line .... so that part is odd ....

What I would personally do , is contact Honda (not the dealer , but Honda itself) , and inquire about this along with the dealer/mechanic work order info (you did not mention if this was just a shop or a Honda dealer doing the work) , and hopefully they will cover the parts cost , as this should not happen for any reason other than a defect (it was bad from the start and took 50 hours to self destruct would be my guess) , but I would definitely get hold of Honda on this ..... ask if this has been found to be a issue with anyone else with a low hour bike reporting a similar issue ...

Sent them an email about this, I’ll let you know what they say.

I just had the same thing happen to my 2018 CRF250R as well. Please let me know what Honda had to say about yours?

Welcome to the site !!

Go to this link (below) and enter your Vin # and see if it shows anything for a Recall , if not , as I mentioned to ejk , you need to contact Honda , as the more people that report this issue , which now seems not to be a isolated incident , and ask them about it , more than likely they will cover it if you tell them someone else had the exact same issue and while searching for a answer to your issue , you came across this topic which proves it is not a isolated incident , and that others may have had the same issue , but just did not post here about it , there seems to be a pattern (I would tell them that) and that others are experiencing the same issue around the same hours , so there has to be significance to that ......

Here is the Honda Recall link:
https://powersports.honda.com/recalls

On a side note , the only recalls I could find doing a quick Google search was a recall for the Clutch Basket on 18 and 19 CRF250R's with the basket breaking and also causing other damage ...

https://www.cpsc.gov/Recalls/2018/offro ... rds-recall

I just had the same thing happen yesterday on my 19, I bought it used from a friend with about 15 hours and have since put another 15 on. Everything seemed fine, came in to adjust my suspension and when I went to restart the bike to continue the starter just free wheeled. Just like OP, found the bolt heads inside the magneto and jammed inside the copper wounds for the stator. Luckily I was able to back them all out with a dental pick enough to grab them with pliers. Ordered a stator and bolts and plan on doing a couple of oil flushes before riding again. The mechanic I have do my bottom ends etc came across this thread when I told him about it, said he's friends with Jade Dungey and he's going to talk to him this coming week to see if he's heard of it happening on both consumer bikes or factory bikes. Seems as if it's not a common enough problem for Honda to take ownership of it, but wanted to post here as well to let people know that it's happening to others out here as well.

Absolutely love this bike but I've had a handful of little issues with it from day one. Try not to be too discouraged

Hello, i have the same Problem on my 2018 crf 2018. It also only has about 50 hours. So did you guys get any feedback from Honda?

Mick

QuickMick ... You can Edit: your first post and change the doubled 2018 to 250 by clicking on the very first square with the pencil in it on the right top side of your post , and then it allows you to edit the post

And you can go to the link I provided in my 2nd post (2 above yours) and see if they have any updates on this issue , or call your Dealer and let them know that you want Honda to know , and hopefully do something about it ... if it is a reoccurring issue I am sure Honda will address it

The issue with the Mapping on the 21 450R is now a free fix at any dealer , Honda got on the ball and is letting everyone who bought one to go to the dealer and get it remapped for free , as there was nothing but complaints about the issue , even in the shootouts(which is how it should be , they take care of it) .... so check the link , then even contact Honda themselves and/or your local dealer

The one thing I do know is , if you let them know something happened that should not have , and you want something done about it , then they should look into it , and usually do

This has just happened to my 2019 crf250r at 26.6 hours. I have done some measuring and have found the sprag clutch retainer is sitting taller than the face of the sprocket not allowing the flywheel to bolt flush. I will be machining the flywheel clearance bore on the sprocket side to 60.5 mm. and will leave the depth the same. I believe this will cure the problem, I would like to have seen some dowels incorporated or shoulder bolts used as the threads have also worn into the flywheel.

Welcome to the site !!

I would encourage everyone posting in this topic to directly contact your Dealer AND Honda itself , the more people that complain about the issue will get Honda to address this ... it is obviously a issue ... So I am sure they will look for a solution and most likely inform everyone who has purchased one , and make them aware of a fix or solution

Where I posted the links above , there should also be a place to contact them about issues , as mentioned above , when they are made aware of issues (like the 21 450R mapping issues) , they act and made all dealers do the mapping for free to anyone with a 21 450 , so I do not see there being any different of a reaction to this issue .... but again , they need you to contact them directly , as this is the only way they will address it with updated parts ....