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Old 05-07-2012, 09:49 AM   #1 (permalink)
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Default 2005 KX250F Fresh rebuild, having problems

Hey guys, i picked this bike up a few months ago from an add or craigslist. The bike was for sale as a project, previous owner tracked it pretty hard. Crank bearing let go. So i got the bike pretty cheap

I took the motor apart replaced the crank with a Wiseco forged crank and all wiseco gaskets and seals. stripped both case halves completely down, washed, and rebuilt with new bearings.

I placed the motor in today, bolted everything back up. Its not running though. When i got the bike it was already taken apart, so i there's a chance i could have missed something when i put it together.

so it turns over, sputters sometimes but wont run. Ive witnessed a few backfires out of the exhaust as well. What do you think is wrong? I remembered to set my timing correctly and checked it a few times. Weak coil? carb issues? im not 100% sure how to set it correctly.


Any and all advice you can give me will be greatly appreciated!
Thanks
-Zach
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Old 05-07-2012, 10:25 AM   #2 (permalink)
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how long was it sitting?
did you clean the carb? its likely clogged.
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Old 05-07-2012, 10:50 AM   #3 (permalink)
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I've seen cams put in 180 degrees off. Not hard to do to be honest.
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Old 05-10-2012, 10:10 AM   #4 (permalink)
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Thank you! Thats the next thing ill check, why is it that is easy to put them 180 out? ex cam had one got on top and one dot in the corner of the head casting, int cam has one dot on the top and one of the bottom corner of that side of the casting, magnito marks on TDC. corrrect?
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Old 05-13-2012, 01:15 PM   #5 (permalink)
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Bump!! Any more info?
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Old 05-13-2012, 07:23 PM   #6 (permalink)
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Sorry didn't see you replied again.
It's easy because even when you have both marks aligned, it doesn't mean the crank is at the correct stroke to be putting the cams in. As far as what marks go where, I'm not sure the on KX, so you'll need to check the service manual. Every bike has different cam markings for timing it.
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Old 05-13-2012, 08:00 PM   #7 (permalink)
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How was the compression? And ur cams are in the right place? Seen exhaust cam and intake cans switched before.

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Old 05-15-2012, 10:25 AM   #8 (permalink)
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i really CANNOT time this thing up. i get my DTC on the flywheel through the sight hole on the cover perfectly and my cams are just slightly off, one is a little below the head. and when i turn the cam to the correct position the TDC mark on the flywheel is outside of the sight glass
BUT if i spin just one tooth over the crank moves to the other side of the sight glass not the middle of it where its supposed to be, i cant move half a tooth so what is going on here!?
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Old 05-15-2012, 10:06 PM   #9 (permalink)
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I got it as close as i could, put it back together and it runs! still not 100% perfect but it does run and idle.

One more question, how does this clutch system usually operate? i cannot roll the bike with the bike in gear and the clutch handle depressed. It will not turn the motor over, so the clutch is slipping a little bit but the wheel still drags. when i have the bike on the stand and i start it up, depress the clutch, and drop it into gear the wheel springs to life and turns pretty rapidly. I tightened the cable down as much as i could. This is my biggest issue at the moment

Thank you!!
-Zach
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Old 05-16-2012, 09:47 AM   #10 (permalink)
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Did you have the head or cylinder milled? Anything that would shorten the distance between the cams and crank? If so, you will need adjustable cam gear to correctly degree your cams.

Did you put a new clutch in? Did you soak the friction plates before assembly? Or did you use the old steels and frictions? Did you assemble the old plates all facing the same direction as the came apart? These things can contribute to why you can't completely disengage the clutch, but I don't think it really matters. My bike harder to push and start in gear, so I don't do it. Put it in neutral to push and start it like the rest of us. As long as you can get the clutch adjusted so that it is functioning properly while riding, I don't see a problem.
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