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I need to disassemble engine to clean out bits of metal...

3.4K views 5 replies 5 participants last post by  wjmrty  
#1 ·
I have an 08 rebel 250 which stopped shifting and then had a grinding sound in the engine. I hauled it in and paid a shop to fix my bike, they showed me something that was under the right hand engine cover had come loose and was being ground on by the clutch pack. (Sorry I just can't recall the other part.) Anyway they fixed that, and I got my bike back.

In no time it was giving me shifting issues again, then shifting locked up again but this time no grinding.

I'll save the cusswords and long story short after taking the two engine side covers off I find metal shavings still in the engine.

Apparently they didn't clean it out in the repair, and I have shavings and crap in my engine case. They went out of business... Now I have to completely take it apart and clean the case out myself, and I have never gone this far into an mc engine. I can't afford to pay anyone anything, broke and stuck. This is my only transportation. :(

At least I assume I have to take it completely apart. I'm sure there's no easy way, like removing the head and flushing?

I have the engine side covers off, I pulled the clutch pressure plate, then there's a weird round head nut with 4 keys in it that holds the rest of the clutch on. Is there a way to get that off without buying a special tool?

Are there any other -special- tools I will need? I have the common stuff.

Any other tips you guys? My ingenious plan is to just start unscrewing everything until there's nothing left to unscrew and it's all apart. Except for that special nut thing. My local shop near me says we have the tool, but we don't sell them or loan it out.:whistling:

Flying blind at zero miles per hour...:banghead:
 
#2 ·
You can buy that tool for around 10 dollars online (link). I think a few people have been able to make one by cutting a 24mm socket.

I will say that I've had this bike apart a lot, and a manual (or Clymers) is a must. I think you can probably get the whole thing apart by just pulling things apart, but putting it back together is a completely different story. Besides just the torque values, there are a few things that I wouldn't have known to install a certain way or to do a certain thing without a book telling me.

In your case, I'd maybe pull the right hand cover, clutch and shifting assembly first. You can then look inside the case from a small opening there, and see just how much metal you need to get out. Maybe you'll get lucky and can use a magnet on a stick to remove some of it.

The thing that worries me, though, is that something just "came loose" in your bike in the first place. Any idea what that part is?
 
#3 ·
Welcome. Hopefully, it's not as bad as your name suggests.

Since you have already pulled the side cases, you should have access to where most of the metal would collect. Check the internal oil screen/filter and remove any metal that may be there. You can flush the case compartment with solvent to wash the shavings out. I wouldn't take it any farther apart than you have. If the metal bits are attracted to a magnet, it would probably be a good idea to install a magnetic drain plug. This will help keep any bits that don't get flushed out from circulating in the oil.

You can remove the special lock nut by grinding off or lifting the skirt/flange on the nut that has been driven into the slot on the shaft. Then it can be turned (lefty loosey) with an old screwdriver blade and hammer. But you are going to need the special tool to install it to the proper torque anyway, so I'd go ahead and invest in one. An option to buying the tool is to make your own with a
Dremel grinder or hacksaw and file. Cut a socket (think I used a 7/8") so it fits the special nut. Do a tag search here for clutch tool and you'll find good info.
 
#4 · (Edited)
Thanks guys. Yea I wish I knew what the other part was too, I can't see wear on anything but the outside of the clutch assembly and from the wear which is a line in the outside I'm guessing it was the shifter arm. Just a guess though.

The clutch basket or whatever it's called, that appears to be aluminum and I think most of my metal shavings are aluminum. That crud seems to find it's way right into the shift drum and make shifting hard and lock up when a big enough chunk gets lodged in there. I wish aluminum was magnetic. :)

Yea I do have both side covers off and was able to clean that up, it's just getting it completely out of the shift drum and interior that's the challenge. I would LOVE to be able to fix this without taking it apart further. Can I use gasoline as a solvent, and try pumping and flushing through the right side rear, there's a hole that reaches into the gear area and maybe with enough work I could flush stuff out? I don't want to ruin the gaskets, already broke on side gasket. $10 for that tool is good, but I really have to try and do this on zero budget. I'm in debt up the wazoo, and I have no credit cards anymore since I now live a cash only but at present cashless lifestyle, so it's not easy to order online.

I have a dremel and 4" grinder so I will see about making the tool if need be, but wow a flush would sure be desireable.