September 26th, 2021, 03:07 PM | #81 |
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I'm not sure what I'm seeing. It looks like a crank journal with nothing out of the ordinary. Is it worn undersize or something? Or was there noticeable rod play? Did the bearing in the rod really spin? It certainly doesn't look bad enough that the bearing seized to the journal and spun.
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September 26th, 2021, 03:20 PM | #82 |
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it is where the connecting rod bearing sits. The connecting rod bearing spun and the two halves got stuck together. Can I replace with one that is a little thicker or just use the standard sized ones?
Thanks Tom |
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September 26th, 2021, 04:44 PM | #83 |
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To answer that you'll need to accurately measure the journal and inspect the rod for damage. If the bearing really spun due to seizing to the journal, I can't imagine the journal doesn't have damage that would require regrinding, but inspecting and measuring will answer that question.
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September 26th, 2021, 06:33 PM | #84 |
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looks like the measurement that got of crank pin shows that it has worn past service limits. I have decided to sell bike because it is going to cost to much to fix.
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September 26th, 2021, 07:38 PM | #85 |
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Sorry to hear that Tom, but I understand. Good luck with future motorcycle purchases!
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October 17th, 2021, 05:48 PM | #86 |
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Did not sell this yet, got everything back together but as i try to bolt the case halves together, it get increasingly harder to turn the crankshaft by hand. Should i get some wet/dry emery cloth and try to smooth out the bearing journals on the crankshaft so that I have just a little more clearance for the crankshaft to turn between the three sets of crankshaft bearings? Tried a different crank shaft from a 1988 ex250 but it fits way to loose. A lot of up and down play.
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October 17th, 2021, 06:45 PM | #87 |
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How hard to turn does it get? Enough to read lb-ft on a torque wrench, or just a little resistance?
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October 17th, 2021, 06:48 PM | #88 |
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probably 40 ft-lbs on torque wrench. No pistons or cylinder installed. Just the crankshaft.
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October 17th, 2021, 07:59 PM | #89 |
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Wow, something is very wrong! When you say you got everything back together, what does that mean? It seems like you did something like get new bearings that are the wrong size.
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October 22nd, 2021, 08:28 PM | #90 |
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I have since ordered a good used crankcase from a 1988 ninja 250 engine and that will match up to the crankshaft that I got to replace the one that was bad. The transmission gears will fit into the new case and I am told that cylinder block will bolt up to case with no problem at all. I will post new pictures once I have everything back together.
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October 31st, 2021, 04:14 PM | #91 |
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Does anybody have the correct bolt sizes and locations for the clutch cover bolts? In other words which holes does the long and short bolts go into?
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October 31st, 2021, 04:23 PM | #92 |
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see ronayers.com or partzilla for partsbook breakdowns by model/year
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gordon@customcarbservices.com Custom Carb Service www.customcarbservices.com |
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October 31st, 2021, 04:47 PM | #93 |
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Partzilla should do it, but if not... you can gently put a long one in, and if it bottoms, try another hole, repeating until it goes all the way in. Then work your way down to the short bolts.
Just never force a bolt in if it might be bottoming in the hole, because you can break a piece of the casting out, with the piece going in the engine. I've heard of aftermarket bolt sets having bolts too long and causing trouble like that. |
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November 1st, 2021, 12:11 AM | #94 |
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General rule-of-thumb is fasteners should have 1.5x diameter in threads engaged. So 6mm bolt will have 9mm of showing before you screw in.
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November 1st, 2021, 05:25 AM | #95 |
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November 1st, 2021, 07:41 AM | #96 |
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ok 2x then. Stick them all in and juggle until they all have equal amounts showing.
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November 7th, 2021, 07:21 AM | #97 |
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Engine is all back together. Newer crankcase, crankshaft, pistons, rings. 150psi cold compression both cylinders. Took out for ride. I still have hesitation between 1/8 to 1/4 throttle. Need to sync the crabs. Biggest issues is not being able to shift back into first gear when coming to a stop usually end up in second instead. And from second to third it feels like I have to move my foot up quite a bit to hit third gear. How can I fix that?
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November 7th, 2021, 08:52 AM | #98 | |
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Quote:
One possible is the you mix up the shift fork or there pettey worn |
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November 7th, 2021, 09:42 AM | #99 |
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there's feature called "positive neutral finder" that uses centrifugal force on ball-bearings between 4th-gear and transmission shaft to prevent shifting into 2nd unless output-shaft & rear wheel is spinning. You may have assembled transmission in way that prevented these ball-bearings from relaxing back onto output shaft. Basically reversing function into "negative neutral finder".
CycleWorld - kawi positive neutral finder
Link to original page on YouTube. Last futzed with by DannoXYZ; November 9th, 2021 at 10:19 AM. |
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November 7th, 2021, 10:37 AM | #100 | |
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Quote:
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November 7th, 2021, 01:07 PM | #101 |
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November 8th, 2021, 01:43 PM | #102 | |
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Quote:
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November 8th, 2021, 07:00 PM | #103 | ||
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If you turn on Captions -> English - jamake, you can follow along with the hilarity...
Quote:
Quote:
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November 10th, 2021, 07:26 PM | #104 |
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Fixed it:
Clutch cable was adjusted so that it would not disengage the clutch plates enough to shift gears very well. So I re-adjusted it and it is working fine. Now to deal with the snow. |
3 out of 3 members found this post helpful. |
November 10th, 2021, 09:49 PM | #105 |
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awsome work!
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November 29th, 2021, 06:19 PM | #106 |
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Still having an issue between second and third gear, It is almost like I have to flick my foot up twice to get it to shift. But when it is on the center stand it shift really easy through the gears. I also have an issue with not being able to see anything behind me in the mirrors. Does anybody now if the aftermarket mirrors they sell with fit on the 1986 Ninja EX250? Also wondering if I should switch to the "short" brake and clutch levers?
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November 29th, 2021, 06:31 PM | #107 |
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I use bar-end mirrors.
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November 29th, 2021, 06:36 PM | #108 | |
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I don't think there any direct bolt on aftermarket mirrors |
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November 29th, 2021, 10:15 PM | #109 |
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Maybe clutch-cable needs to be tightened just tad more?
Also make sure both levers coming off shift-rod is oriented 90-degrees to it. One connects to transmission and one to shift-pedal. Any mirror that fits pre-gen '88-07 bikes will also work on '86-87. |
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March 10th, 2022, 07:30 AM | #110 |
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My fuel tap does not work right in on position any harm with leaving it in the prime position with a shut off valve hooked inline?
Oil did smell a little gassy. Also got a dead spot between 5 and 6K rpm. Last futzed with by tomsninja2020; March 10th, 2022 at 09:38 AM. |
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March 10th, 2022, 09:14 AM | #111 | |
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You want to do a full blown clean of the carb and replace all seal and gasket If never done a carb talk to ducatiman Last futzed with by shspvr; March 10th, 2022 at 02:08 PM. |
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