need help but i know im going to sound like an idiot

[txnili]

I bought my daughter a 2004 ninja 250 with an 05 motor in it for Xmas. It was apart and in pieces when I got it but I've torn my Suzuki Katana 750 apart without any issues. My problem is a bad knock when its running. Don't think its normal. Anyway I did an oil pressure test as well as a compression test. Both look great actually so thought it might be valve clearance. Now here is where you might think I'm stupid. My bike is air cooled and this is my first time with one that has a radiator. Took off head cover and there is antifreeze inside of heads. Is that normal? Before I go any further if that is not supposed to be inside there I need to figure out how it got in there. Also it has no air filter I'm waiting for it to arrive after ordering it so I know the air mixture is way off which could also be making it sound weird to me I am used the the sound of my 750

[crimsondragon]

So you found antifreeze mixed in with the rockers valve springs underneath the valvecover? No that is not normal and that would definitely destroy your bearings. Coolant doesn't make for a great lubricant. Well, it does for the water pump, but not cranks and rods. I can't remember exactly how the coolant runs through the head but I do know there are a couple of tubes leading into it. I'd start with checking for cracks around that area.

[txnili]

Yes and I did not think it belonged there. Ok now I know its time to just pull the motor completely out and tear it completely down. Thank you so very much. Now my biggest problem is going to be finding all the gaskets to replace. Only one I can find is head and valve cover so far. Any ideas where to look for complete engine gasket kits?

[Motofool]

Originally Posted by txnili

Yes and I did not think it belonged there. Ok now I know its time to just pull the motor completely out and tear it completely down. Thank you so very much. Now my biggest problem is going to be finding all the gaskets to replace. Only one I can find is head and valve cover so far. Any ideas where to look for complete engine gasket kits?

Before you go crazy on pulling the engine apart, verify that the coolant intrusion did not hapen during disassembly.
Check the oil in the crankcase, coolant may be there as well.
The clutch naturaly makes a sound like the one you describe.

[Chicagobob]

Some EX250 engines knock at slow idle, which is not a problem, and they all have noisy valve trains (if they are adjusted loosely enough), so don't be too quick to tear the whole thing down.

[Motofool]

Please read these:

http://faq.ninja250.org/wiki/Hints_%...lve_Adjustment
(Look for "Leaking coolant pipe")

http://faq.ninja250.org/wiki/What%27..._the_clutch%3F

http://faq.ninja250.org/wiki/What_is..._the_engine%3F

http://faq.ninja250.org/wiki/Cooling_system

http://faq.ninja250.org/wiki/EX250_parts_diagrams

http://faq.ninja250.org/wiki/Cam_cha...sioner_removal

[Ghostt]

@txnili

If the engine is in fact shot, don't waste your time, money and effort, trust me, find another low miles replacement, check the sale section in this forum, there is always something floating around there.

Question: does the knocking noise go away if you pull in the clutch?

[txnili]

Thanks everyone as long as the block isn't cracked I have no problems fixing and rebuilding a motor. Even though I'm not a mechanic I have the ability to fix anything except a DVD player. Those I would say to hell with trash and replace. But a motor helps me learn something new. Don't know about clutch I started it in neutral and had no reason to pull clutch. Knocking sound was coming from head cover. Only thing I was unsure of was antifreeze being up in with the valves. I already torn it out and apart the head gasket has failed it is in bad shape and around the piston shaft it has been chipped so I ordered a new one.

[txnili]

Thank you motofool. I bought the Haynes book and read thru it about 6 times and watched countless YouTube videos before I decided to tear into this. When I saw the coolant in with my valves though it made up my mind to figure out what is causing that and stop it.

[Motofool]

Originally Posted by txnili

Thank you motofool. I bought the Haynes book and read thru it about 6 times and watched countless YouTube videos before I decided to tear into this. When I saw the coolant in with my valves though it made up my mind to figure out what is causing that and stop it.

You are welcome.

These engines get twisted heads as soon as the coolant level is too low.
Then coolant leaks down into the crankcase and then it gets inside the lubrication circuit.

In other words, if present around valves, it has been everywhere else and has damaged the main bearings.

Draining the oil will tell you if that is the case.

It is not rare, however, to have coolant leaking from the tube-head conection during removal of the head cover.

[Racer x]

If you could identify the coolant under the valve cover and it was not mixed with the oil then it spilled in from the hose at the back of the head.
Knocking sounds can be from the clutch basket. If it has oil pressure and compresson it might be that.
Or not. Just go slow and photograph as you go.
Get a manual and don't reise rod bolts. Also if you can find a machinest befor you start. Local is best or thee are a couple people on the forum that do machine work.
These engines are getting scarce fast so buying another is still an option.

[Ghostt]

http://faq.ninja250.org/wiki/What%27..._the_clutch%3F

[txnili]

Drained the oil and somehow it is not inside the crankcase it was only up with the valves. I did get a manual and have read it several times already the head gasket is fried bad and chipped around piston shaft. I got a new one on the way. Not sure how I could have leaked it from hose above. I separated it first from top pulled up cover just enough to release tab then put it back on upside down so fluid would have to travel up 90° bend first and shoved a papertowel in it but apparently I am not as careful as I thought and looks like I did spill some somehow. Not sure how to send a pic on here or I would show you all the head gasket.

[Motofool]

Originally Posted by txnili

........... Not sure how to send a pic on here or I would show you all the head gasket.

That O-ring leaks as soon as the tube is moved.

Just click on the paperclip icon on top of your reply window and attach it.
Check the type of file and the max size pic allowed.

[txnili]

20150213_115831.jpg

20150214_221930.jpg

[txnili]

Thanks motofool I've been using quick reply box on bottom

[Alex]

You can hit the "go advanced" button at the bottom of the quick reply box, and it opens up into a normal interface with all of the bells and whistles.