June 19th, 2014, 01:44 PM | #1 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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SOS ('03 ninja 250)
In Berkeley Ca, I recently was shifting into first at a stop and heart a clunk and ever since it has been BOUNCING when i'm in gear (any gear), in nuetral it's perfectly fine (including at speed when i pull in clutch). I checked the two outer sprockets and neither are missing teeth. I am 100% sure it's in the transmission. I have never worked on the transmission or even have any idea how to start on it. The bike is driveable but I'm trying to avoid driving whenever possible. I can hear the broken bit rattling around in the transmission when i pull in my clutch to come to a stop, and it's not a pleasant feeling
If anyone has any helpful places i can go to get it fixed, or any spare transmissions laying around... I work 60 hours a week as a dishwasher at a restaurant and don't have any free time and I NEED it fixed asap or my summer is going to turn into a hell hole. Feel free to pm me or comment! |
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June 19th, 2014, 03:17 PM | #2 |
CPT Falcon
Name: J.Emmett Turner
Location: Newnan, GA
Join Date: Apr 2009 Motorcycle(s): '08 CP Blue EX250J, '97 unpainted EX250F, 2nd '97 unpainted EX250F (no engine), '07 black EX250F Posts: A lot.
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Oh boy. I've been in similar situations where I needed my bike fixed ASAP but had too many obligations and not enough money.
Good luck! |
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June 19th, 2014, 03:20 PM | #3 |
The Corner Whisperer
Name: Chris (aka Reactor)
Location: Northern KY
Join Date: May 2011 Motorcycle(s): 2010 250 (track), 1992 250, 2006 R6 (street/track), 2008 R6 (track) Posts: Too much.
MOTY 2015, MOTM - Nov '12, Nov '13
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Good luck from da KY!
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June 19th, 2014, 04:23 PM | #4 |
wat
Name: wat
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since it is in any gear and not in specific gears, it is probably not the transmission. more likely the outer clutch hub gear which connects the engine to the clutch/transmission
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June 23rd, 2014, 05:29 PM | #5 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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It is specifically worst in 1st gear (happened when i was getting into first), but can be felt in all gears... (seeing as if you look at the internal workings of the transmission it uses all some of the same inside gears for multiple different gears (1-6).. I could try checking the clutch first and if that's not it then i'll have to check the tranny. does anyone have a tutorial for clutch access and replacement?
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June 23rd, 2014, 05:39 PM | #6 |
ninjette.org member
Name: John
Location: Crossville, Tn.
Join Date: Oct 2010 Motorcycle(s): '02 Ninja 250, '98 Triumph Sprint 900, '69 H-D Sportster XLCH 900 Posts: 80
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Manual
I know you don't want to hear this but.....get a manual and start reading.
j98sprint |
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June 23rd, 2014, 08:28 PM | #7 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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Alright, where can i get a manual that can help me out?
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June 28th, 2014, 02:28 AM | #8 |
Phoenix Salvage
Name: Mac
Location: AR
Join Date: May 2014 Motorcycle(s): 2007 Ninja 250R Posts: 71
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official 86-07 ex250 factory service manual: (Part #99924-1066-01)
official 88-07 ex250 manual supplement: (Part #99924-1109-66) http://www.ronayers.com/SM-EX250EF-E...-P4210780.aspx Service manual: $28.31 at ronayers.com http://www.ronayers.com/SM-SUPP-EX250F-P4210934.aspx supplemental manual: $25.88 ar ronayers.com An inquiry with uncle google should also reveal a digitally scanned version, but you have legality/possibly incomplete aspect issues to deal with on that route. Good luck with the repairs/diagnosis!
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June 28th, 2014, 03:07 AM | #9 |
ninjette.org certified postwhore
Name: Paul
Location: UK
Join Date: Apr 2014 Motorcycle(s): Ninja 250, Yamaha RS200 (classic) Posts: A lot.
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important note Sorry for the bad news but The bike is not "still driveable". If there is a sizeable chunk of metal roaming around in there sooner or later it is going to jam the gears and lock your back wheel.
and you won't like that when it happens Is that $200 craig list engine we were discussing last week still around? It might be quicker to buy it and swap, you can then fix yours at your leisure and sell one or the other later to recover the cost. https://www.ninjette.org/forums/showthread.php?t=186159 Okay it's in Atlanta but check ebay, breakers etc' |
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June 28th, 2014, 01:09 PM | #10 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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I think that would have happened by now, since i drove my bike from weed california to berkeley california (5 hour drive) with no problem of that kind... I am unsure as to if it really is the transmission... and i have ordered the manuals but they are in the mail.It could be as simple as the clutch.... When my bike is not warmed up, if i pull in the clutch lever all the way and downshift into first my bike always dies. ... thoughts?
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June 28th, 2014, 01:21 PM | #11 |
ninjette.org certified postwhore
Name: Paul
Location: UK
Join Date: Apr 2014 Motorcycle(s): Ninja 250, Yamaha RS200 (classic) Posts: A lot.
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Can you be a bit more clear what you mean by "bouncing" like at what rate, up and down or back and forth?
Does it change rate if you change gear at constant speed? Just try trying to model the behavior in my head |
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June 28th, 2014, 01:45 PM | #12 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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It's forward and backward, and i can't recall if it's worse at higher or lower rpms, or speeds for that matter.... but I'll go out for a quick test here shortly and get back to you.
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June 28th, 2014, 01:51 PM | #13 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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Also trying to find a good clutch kit because I'm sure it's well overdue for a clutch replacement regardless, any advice on where to get one for a good price?
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June 28th, 2014, 01:58 PM | #14 | |
ninjette.org certified postwhore
Name: Fish
Location: co
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Quote:
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Hey Unregistered never go faster than your brakes can be applied... |
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June 28th, 2014, 02:13 PM | #15 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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I know i'm doing more harm but i HAD to get down here from oregon, so i had no choice. I'm replacing the clutch plates/springs and doing an oil change sometime this week and we'll see if that helps with anything, it's well overdue for one, seeing as my ride has got 33k miles on it... YIKES
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June 29th, 2014, 12:56 PM | #16 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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Update. So at constant speed it does it and seems more serious at higher rpm(lower gear at same speed)
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June 29th, 2014, 01:20 PM | #17 |
Long Time Rider
Name: Blue
Location: Charlotte, NC
Join Date: Sep 2010 Motorcycle(s): 2009 Kawasaki Ninja 250R Posts: A lot.
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Any serious transmission damage will be evident by metal shavings in the oil. If you drain the oil and remove the oil screen you will see it.
Also what is the condition of your chain? Is it tight in spots and loose in others? If so this can also cause damage (bushings in particular). You should get the rear wheels off the ground and inspect the chain and rotate the wheel to see if there is any resistance while turning the wheel in neutral. |
1 out of 1 members found this post helpful. |
June 29th, 2014, 01:28 PM | #18 | |
Daily Ninjette rider
Name: Hernan
Location: Florida
Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot.
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Quote:
It is a clutch or crankshaft related problem; forget about the transmission. Take a look at this: https://www.ninjette.org/forums/showthread.php?t=182263 When you pull that lever, the cable twists that 13102 shaft-cam (coming up from the top of the right cover). Then the 46102 clutch rod pulls everything out against the resistance of the clutch springs and the crankshaft's bearings. Then, the ugly noise appears. The solution may be as simple as changing the oil.
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Motofool .................................Never ride faster than your guardian angel can fly "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí |
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June 29th, 2014, 02:43 PM | #19 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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I will check the oil and clutch asap and report back
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June 29th, 2014, 07:02 PM | #20 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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Also My radiator fan does not work, I've replaced fan itself, didn't fix it, checked the fuse(which was good) and need to know what to replace next.... The thermostat switch or the water sensor plug or thermostat....?
Last futzed with by Caliboy2010; June 29th, 2014 at 08:25 PM. |
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June 29th, 2014, 08:40 PM | #21 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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Should i invest in anything else in the clutch other than the springs, and the friction and steel plates?
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June 29th, 2014, 08:59 PM | #22 | |
Daily Ninjette rider
Name: Hernan
Location: Florida
Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot.
MOTY - 2016, MOTM - Dec '12, Jan '14, Jan '15, May '16
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Quote:
http://faq.ninja250.org/wiki/How_do_...ping_clutch%3F
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Motofool .................................Never ride faster than your guardian angel can fly "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí |
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June 29th, 2014, 09:12 PM | #23 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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Is that switch the one that goes into the radiator or the one that goes into the thermostat housing?
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June 29th, 2014, 09:25 PM | #25 |
Daily Ninjette rider
Name: Hernan
Location: Florida
Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot.
MOTY - 2016, MOTM - Dec '12, Jan '14, Jan '15, May '16
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27010 is the switch that commands the fan.
Don't go crazy buying parts that may be OK; explore and test first. Follow my previous links for ways to test it.
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Motofool .................................Never ride faster than your guardian angel can fly "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí |
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June 29th, 2014, 09:26 PM | #26 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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Thank you sir, and yeah i'm on a budget. I'll do the oil change, clutch replacement, and thermostat fix next time i get a few days off work (probably the 5th of july) and report back!
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July 5th, 2014, 09:11 AM | #27 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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Another thing that was wrong... Chain was stretched far too far and had many kinks and rust... (bought a replacement one and a chain breaker tool) I want to buy new sprockets with my chain so that it wears evenly, where can i get a 15t front sprocket with the 2 wholes which are grooved the same as the bolts for the sprocket holder?
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July 5th, 2014, 02:09 PM | #28 |
CPT Falcon
Name: J.Emmett Turner
Location: Newnan, GA
Join Date: Apr 2009 Motorcycle(s): '08 CP Blue EX250J, '97 unpainted EX250F, 2nd '97 unpainted EX250F (no engine), '07 black EX250F Posts: A lot.
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Part numbers:
http://faq.ninja250.org/wiki/What_re...t_Part_Numbers Replace "xx" with 15 for 15-tooth. |
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July 5th, 2014, 02:53 PM | #29 | |
ninjette.org sage
Name: Aaron
Location: Winder, GA
Join Date: Jun 2012 Motorcycle(s): 2013 Ninja 300 Posts: 718
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Quote:
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July 5th, 2014, 07:14 PM | #30 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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Thanks guys, hopefully all my parts will be here by thursday since i have thursday and friday off work....
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July 21st, 2014, 07:47 AM | #31 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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So all was fixed, but the problem was actually just the chain that caused the lurching and such... a new problem has arose....
After my most recent oil change I have come to the realization that the threading in my oil drain bolt is stripped, not the bolt itself but the inner threading, what can I do? If anything.... |
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July 21st, 2014, 07:59 AM | #32 | |
Private Joker
Name: Ben
Location: Towson, MD
Join Date: Nov 2012 Motorcycle(s): '99/'01 Ninja 250 "sketchy", '13 Ninja 300 "yoshi", '03 GSXR 600 "merlin" Posts: A lot.
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Quote:
if so then this product is designed for you: http://www.loctiteproducts.com/p/10/...r-Blue-242.htm
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July 21st, 2014, 08:20 AM | #33 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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I was thinking more of a rethreader...
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July 21st, 2014, 08:37 AM | #34 |
Private Joker
Name: Ben
Location: Towson, MD
Join Date: Nov 2012 Motorcycle(s): '99/'01 Ninja 250 "sketchy", '13 Ninja 300 "yoshi", '03 GSXR 600 "merlin" Posts: A lot.
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you're probably right on that idea, I forgot those were made
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I see you over there seeing me, do you see the me I think you see? |
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July 21st, 2014, 10:58 AM | #35 |
ninjette.org sage
Name: Aaron
Location: Winder, GA
Join Date: Jun 2012 Motorcycle(s): 2013 Ninja 300 Posts: 718
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I have heard here on the boards recently that the metal on the oil pan is too thin to have new threads cut (probably possible, just not advisable.) Might want to look into getting another. Someone who knows better feel free to correct me.
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July 21st, 2014, 02:07 PM | #36 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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Getting another what?
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July 21st, 2014, 03:03 PM | #37 |
ninjette.org sage
Name: Aaron
Location: Winder, GA
Join Date: Jun 2012 Motorcycle(s): 2013 Ninja 300 Posts: 718
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The oil drain assembly. It's part number 14090-1350 for your bike, I believe.
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July 21st, 2014, 08:14 PM | #38 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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Well for now, i drilled it out and rethreaded it... now it's a 14mm drain bolt instead of the stock 12... I flushed the oil through with a few older oils and then a quart of new oil, completely drained it, and put the new plug in and a new oil filter and new oil. I'll check tomorrow to see if any oil drained overnight...
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July 22nd, 2014, 03:54 PM | #39 |
ninjette.org member
Name: Steven
Location: Corvallis, OR
Join Date: Apr 2014 Motorcycle(s): 2003 Ninja Cafe Posts: 56
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Still leaking oil, the drain plug gasket that came with the 14mm plug is not a rubber oring and that could be the problem, i'll be going to buy new oil and a 14mm oring today to see if that does the trick
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July 24th, 2014, 11:47 PM | #40 |
meh
Name: Joe
Location: SoCal
Join Date: Apr 2013 Motorcycle(s): 2002 EX250F Cafe/Streetfighter Project Posts: 60
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If you cannot get that drain plug to stop leaking, there is another option.
You can completely seal up that drain plug (clean up all the oil, JB weld, and safety wire) and purchase the oil drain plug assembly from the newer generation ninjette. Everything is a direct fit so it's just a bolt on application. The only downside is that it reduces your clearance but it shouldn't matter unless you're jumping curbs. There is a guide somewhere on the faq.
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