honda bike, good compression, wont start

[travgag]

yea i took the cover off and the main gear is good, I thought it was maybe the ratchet gear or something but the entire spindle seams to be fine, # 2 spins as the motor doesn't turn over. so that's not the problem

look here's the spindle

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Splitting the case, il have to get a a few gaskets that il have to replace, maybe even a head gasket ? and i think your right that its #18 thats stripped

you've been a great help Townsends thanks

 

[TownsendsFJR1300]

yea i took the cover off and the main gear is good, I thought it was maybe the ratchet gear or something but the entire spindle seams to be fine, # 2 spins as the motor doesn't turn over. so that's not the problem

look here's the spindle

Lowest price guarantee on parts / accessories for Honda Motorcycle, ATV, Watercraft, Scooter - OEM parts for less

Splitting the case, il have to get a a few gaskets that il have to replace, maybe even a head gasket ? and i think your right that its #18 thats stripped

you've been a great help Townsends thanks

No, problem.

I've never had an XR apart but their pretty similar to the old Yamaha YZ's, AT1's, DT's, Suzuki's, Kawasaki's I grew up on and split many a case..(second idler gear on a AT1 125, both kick starter gears on the same bike too, main crank lower bearing on a YZ 125 (fried in in a MX race many moones ago), replaced both crank cases on a Kawasaki big horn 350 single, 2 stroke (my friend thru the chain thru the left case), a Kawasaki 125 street bike, 2 stroke- bent shifter forks (she couldn't afford new forks so we bent them back, worked great!)...


Why your right there, that entire assembly should come out as a unit (pay attention to any shims on either end of the assembly). Just make sure, that main shaft and anything on that all the splines are fine and that the assembly is sitting in the case correctly.

I say this as splitting cases is quite a bit more work to access that inner gear..

If all is fine with the outside kick starter assembly and you have to split cases, try to find a gasket set (head gasket, cylinder base gasket, side cover gaskets, etc).

The main center case usually DOESN'T USE a gasket but a specific case sealer.

I've used "Yamabond", I'm sure Honda has their own version (before squeezing out the tube, manipulate the sealer inside the tube to make sure its mixed very well, sometimes thin sealer will come out before the thicker, good sealer).

Make sure you DON'T scruff up the inner case surfaces (or any surfaces for that matter) and upon re-assembly, get the inner case surfaces super clean (no gasket material, oil residue, etc). A light to medium coating of the Yamabond (or Honda equivilant) on both surfaces is all that's needed. Button it up the main cases as quickly as possible.

Ther transmission should sit in one side of the case (I don't know which for that engine), probably the left case(with the main, clutch shaft sticking out). If it does, that kicker gear is right there and should pop off with the bushing.

Make sure, again, upon re-assembly, the transmision turns freely, the shifter forks, shafts they ride on, are all in place as well...

If there's any binding, somethings wrong, stop and re-check..

 

[travgag]

Sounds like fun, ive done a bunch of stuff like that all to save money and do it myself, etc..

gotta love it ! and now ill know how loads of stuff works because il have work on them all !

so i found a gasket kit like you said for 35 $ and now to pull the motor, take loads of photos and see what the problem is !

thanks for the tips, !

I will keep you posted

 

[TownsendsFJR1300]

You'll be fine, just go slow and pay attention to any shims on the ends of all the shafts...

I enjoyed doing that kind of stuff, all those bikes mentioned above were done when I was 15-17 years old without a manual (we had to do it yourself, too broke back then).

More recently, my last 2 KLR 250's needed needed major repairs, on the 1989 250, the left main crank bearing failed every 32,000 miles and again at 64,000. My 05 LS bearing was getting loose at 28,000 miles... That engine was considerably more involved with double over head cams, multiple balancers, water cooling, 4 valves per cylinder, engine mounts integrated into the rear suspension(a bit trickier removing the engine when the swing arm is now free)..

Your bike shouldn't be bad at all...

 

[travgag]

Yea its fun !

sounds complicated, my fz 600 '86 is dual cam but no water pump etc..

good luck !

 

[travgag]

Update !

so after two weeks of waiting for parts and finding time to work on the bike i started to put it back together,

this was the motor apart

it took me a while to get the two gear spindles together, i got it shifting and everything, i got the case and cylinder together and when i turned it over by hand and the ratchet is clicking, and if you turn the motor over the other way it tightens the spring, i think i put the lobe on the spindle in the wrong place, it was aiming to the left and not up like in the photo and its not hitting the bolt #13, which is how it disengages ?

Honda Motorcycle Parts, ATV Parts, Watercraft Parts For Less, Microfiche.

now i have to take the case back apart and investigate,

 

[TownsendsFJR1300]

All the Yamaha kick starters I've worked on, everything was located just under the clutch cover. The main kick starter assembly sat in the case, the kick starter idler gear was adjacent to that assembly lost some teeth as did the main kick gear(1969 ATI 125cc).. There was a part of the assembly that used the block to stop the assembly from rotating, your bolt #13 may supposed to do the same thing, dunno...

Your set up is new to me but as you stated, re-check your assembly procedure.

BTW, did you find any gears/parts worn/broke/ loose?

 

[travgag]

got it figured out boys !

so yea after taking this thing apart three times, and cursing alot trying to get the gears to mesh, the shifting forks in, the shift barel lined up,trying to hold the kicker in place with spring pressure on it, and many other little things,

the motor is now in the bike, just have to set the timing again and see if it starts ! i will sunday hopefully

and yes i did find two teeth in the case and 3 more worn off, il post photos also,
88 $ later, problem should be fixed,

 

[travgag]

So it runs and shifts good, i set the valves and changed the rear chain, the timing chain, those two gears for the kicker, and also the one bearing kinda thing on the cam,

look at the gear that had the most damage, three shaved down teeth and two missing


cheers !

 

[Hellgate]

Cool project, well done!

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