March 3rd, 2019, 12:28 PM | #1 |
ninjette.org newbie
Name: MC
Location: USA
Join Date: Mar 2019 Motorcycle(s): NA Posts: 9
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2010 Ninja 250 starter gear holder broken and flywheel gear broken
Hi, just bought my first project bike and already found the problem. For one the flywheel sprocket is missing teeth, and the starter gear holder in the case is broken. I know I need to replace the flywheel sprocket, but how do I fix where the starter sprocket is held? Can I take it to a machine shop? Here are some pics. Bike only has 700 miles on it. I'm in 850 right now. The current plan is to get everything else on the bike 100 percent. Bump start it make sure everything works and rides well then fix the electric start. But I have it apart now was curious how to fix it.
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March 3rd, 2019, 02:20 PM | #2 |
CCS Amateur #501
Name: Dave
Location: Iowa
Join Date: Jun 2015 Motorcycle(s): '09 250 SE 'Booger' Posts: 406
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Ouch!
Im thinkin a set of used cases is cheaper than the welding and machining you would need to fix that. |
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March 3rd, 2019, 02:35 PM | #3 |
ninjette.org newbie
Name: MC
Location: USA
Join Date: Mar 2019 Motorcycle(s): NA Posts: 9
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March 3rd, 2019, 04:11 PM | #4 |
CCS Amateur #501
Name: Dave
Location: Iowa
Join Date: Jun 2015 Motorcycle(s): '09 250 SE 'Booger' Posts: 406
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If you are payin someone else to do it, your only cost effective choice is to buy a used engine and replace it altogether. Im guessing itd be near $1k to have a pro change the cases.
Changing an engine isnt that tough. No special tools needed really. |
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March 3rd, 2019, 04:14 PM | #5 |
ninjette.org newbie
Name: MC
Location: USA
Join Date: Mar 2019 Motorcycle(s): NA Posts: 9
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Can you find a source I can reference on the procedure to change out the case from start to finish so I can get a gauge on how hard the process will be?
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March 3rd, 2019, 04:43 PM | #6 |
CCS Amateur #501
Name: Dave
Location: Iowa
Join Date: Jun 2015 Motorcycle(s): '09 250 SE 'Booger' Posts: 406
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The factory service manual is what you want. Google "ex250 service manual pdf". For the second generation 250, theres a fuel injected version and carbed version if the service manual.
I ended up having to get a puller for the rotor and impact gun for the clutch and sprocket nut. If you buy a set of cases, make sure you are getting a matched set. Half the ebay sellers are selling just the upper or lower but they are machined as a set and meant to be used as a set. |
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March 3rd, 2019, 05:12 PM | #7 | |
ninjette.org newbie
Name: MC
Location: USA
Join Date: Mar 2019 Motorcycle(s): NA Posts: 9
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March 3rd, 2019, 06:00 PM | #8 |
CCS Amateur #501
Name: Dave
Location: Iowa
Join Date: Jun 2015 Motorcycle(s): '09 250 SE 'Booger' Posts: 406
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I cant help you one way or another on that. Im curious to know how the starter gear breaks like yours did.
If you try to start it up as is, you run the risk of those broken metal bits getting stuck in a bad spot and wrecking the internals. So definately find all the metal bits first and make sure the crankshaft and sprocket turn freely. |
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March 3rd, 2019, 06:05 PM | #9 | |
ninjette.org newbie
Name: MC
Location: USA
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March 3rd, 2019, 06:27 PM | #10 |
CCS Amateur #501
Name: Dave
Location: Iowa
Join Date: Jun 2015 Motorcycle(s): '09 250 SE 'Booger' Posts: 406
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There is a catch screen that would catch any larger bits before getting to the oil filter. Remove the little sump that has the oil drain bolt on it, the screen is right on top of it.
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March 3rd, 2019, 09:27 PM | #11 |
ninjette.org certified postwhore
Name: AKA JacRyann
Location: Mesa, AZ
Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot.
MOTY - 2018, MOTM - Nov '17
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When I bought my 2008, it had sat for couple years. Carbs gummed up and in my attempts to get it running, I hydro-locked engine due to petrol leaking past float-valves and filling engine.
Went to crank and it had slow spin, caught 1-2 puffs, and made scratching noise. Result was 4 broken teeth off ring gear. I managed to find all pieces which had stuck to stator coils. Welded teeth back onto starter gear and it'a been working fine since. Seems worse damage in your situation with broken cases. Personally I would have no problems welding case back together. But you may have difficulty finding someone qualified to do work. And cost may be prohibitive compared to used set of cases. Might as well rebuild it in process with new bearings, rings and seals. Last futzed with by DannoXYZ; March 6th, 2019 at 12:24 AM. |
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March 5th, 2019, 06:50 PM | #12 | |
ninjette.org newbie
Name: MC
Location: USA
Join Date: Mar 2019 Motorcycle(s): NA Posts: 9
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