[SOLIDSNAKE367]

hey im new to the forums and to fixing bikes i have a 2005 crf250r and I recently replaced the crankshaft and piston, once the rebuild was done and everything was put back together I stared to try kickstarting it and it would not start, I tried pulling the killswitch and it backfired once I have no clue what the problem is also my clutch seems to be not engaging when I put the bike in gear and try to pull the clutch it does not let the bike roll like normal, also this is my first rebuild so im guessing i probably did something wrong but i made sure all the tdc marks lined up so any help or ideas are much appreciated thanks

[crfsonly]

welcome to CRF's Only. first thing i would verify is the timing is correct. it is very easy to be one tooth off. also, if the carb set with fuel in it you need to replace the jets.

ken

[carters2]

I would agree I think your timing is off. As far as the clutch that is normal. Cold oil causes the fibers to stick to the steel plates causing the clutch to remain engaged.

[SOLIDSNAKE367]

alright cool I will just have to open it up and check the timing, I had one question on that when lining up the the main shaft with the balancer and the chain on the camshaft sprocket and the flywheel does everything have to line up at the same time.
im pretty sure its the cam shaft or the fly wheel as for the main gear and the balancer shaft markings they lined up perfect i thought the cam sprocket was good but this is my first time could be wrong thanks a lot, ohh and ill make sure to change the jets too.

[Lieder245]

Sounds like a timing issue. Like they said in the other posts, it can be easy to be on tooth off.

Are you doing the rebuild due to crank failure or a dropped valve?

If yes- your issue may be that the camshaft gear has spun on the camshaft. All your lines will line up but timing will still be off and cause it not to start.

Let us know!

[SOLIDSNAKE367]

ya almost every single bearing came out from the connecting road and got eaten up inside there was a lot of brass in the bottom end, but it was due to crank failure before that the bike ran great, but the crank completely went out and i couldnt even kick the bike

[SOLIDSNAKE367]

so does that mean the sprocket turned with out the shaft or shaft without sprocket, im not sure what that means, i though that the cam shaft and the sprocket that connects to the camchain are one piece??

[Lieder245]

The cam sprocket is pressed onto the camshaft. They are two separate pieces.

If the engine experiences a sudden seizure (crank locks up or valve drops) the sudden stop can cause the sprocket to move slightly and thus throw off the timing.

The easiest way to find out if that is the problem is to take a known good one out of a running bike and install it to see if it will start.

Any of your riding buddies have a good running 250 that they could borrow you their camshaft?

[SOLIDSNAKE367]

it wasnt a sudden seizure i believe, not really sure my brother was riding it, all he said was that it died on him and wouldnt start, so hold on the cam sprocket is pressed on the cam shaft so when you set to time it right the whole cam should be turned to get it lined up right, so in order to get it lobes pointed to the back you would have to move the whole entire thing if that is so i think my cam shaft might be effed to hell i think the sprocket spun freeley hahah that doesnt sound very cheap

[SOLIDSNAKE367]

actually i take that back i dont think it spun i was just thinking crazy but i dont believe it was a hard seize maybe its ok, all i do know is the timing was off when the left side was lined up with the case marker the flywheel was off. havent tried to fix it yet so well see what happens

[SOLIDSNAKE367]

So I got my bike started and it runs sounds good bit my bike wont cone out of second gear clutch will not engage either anybody have anybody have any ideas ???

[crfsonly]

yep..something's wrong. are you using a service manual for these repairs?

[SOLIDSNAKE367]

ya all the gears are installed exactly the same, but when the bike runs just would not come out of second, we put the shift lever on while it was opened up and the gears all open and close through the gear it looks like is there any ways to make sure the gears cycle while the crankcase is open???

[crfsonly]

the transmission must be installed EXACTLY as mentioned in the service manual. the thrust washers not only have to be in the correct location but also the correct orientation where noted. same with the bushings and spline washer. any deviation and you'll have issues. also, forks are marked and must be installed correctly. anything, even the slightest error and you'll have issues. if you are trying to do this from memory or photos and not the honda service manual you need to get the manual and follow it with precision. if you have, then you must have one or more trans parts damaged.

[hall_philip]

i recommend you take it to a shop and have someone that knows whats going on help you out. a bottom end has alot of moving parts and is not a good starter job for a new mechanic. im guessing your shift forks are in a bind in the case, shift barrel is in a bind. or you didnt get the shift fork(s) on the cog gear(s). it could be costly to your whole motor if you dont do a proper rebuild.