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 Post subject: 250 Engine Tear Down Pictures
PostPosted: Sat Jan 29, 2011 11:38 pm 
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Joined: Jun 14, 2008
Country: USA
State/Province: TX
City: Lancaster
Couldn't decide if this was best posted in the dead horses or wrench bending. I trust a mod can move it if I made the wrong Choice.

As I have chronicled elsewhere, I had to replace my countershaft. This entailed taking the engine all the way apart and cracking the case. The only thing I didn't have to do was mess with the crankshaft.

I have often, on this and other jobs, longed deeply for pictures better than clymers gives me. Clymers often has no pick. When it does they are small, black and white, and often of a different model bike, since the manual covers multiple models.

I am now in the process of attempting to put the engine back together. (I saw attempting because I am clearly in over my head.) As I do so, I intend to take as many pictures as possible in the hopes that they will help someone else down the road.

I am using my phone's camera in a poorly lit garage. Sorry, this is the best I can do. Hopefully it will be useful.



These pics are of a 2004. Your engine may vary. 80's rebels will likely vary more than 2000's models. I cannot gurantee that I am putting this back together correctly as I am a rank amateur. Please take these as a resource, but not as gospel!


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 Post subject: Re: 250 Engine Tear Down Pictures
PostPosted: Sat Jan 29, 2011 11:45 pm 
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Joined: Jun 14, 2008
Country: USA
State/Province: TX
City: Lancaster
Right side of case






Left side of case.





Close up of where the transmission shafts will go.



Mainshaft, countershaft and gears installed.




Shift forks. (note that clymers thinks there are only two!



Shift drum installed


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 Post subject: Re: 250 Engine Tear Down Pictures
PostPosted: Sun Jan 30, 2011 12:03 am 
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Joined: Jun 14, 2008
Country: USA
State/Province: TX
City: Lancaster


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 Post subject: Re: 250 Engine Tear Down Pictures
PostPosted: Sun Jan 30, 2011 8:38 pm 
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Joined: Oct 24, 2008
Motorcycle: 2009 Honda Rebel 250
Rebel: 250
Country: USA
State/Province: TX
City: Dallas
Cool. Thanks for posting these.

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Loud ties save lives


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 Post subject: Re: 250 Engine Tear Down Pictures
PostPosted: Tue Feb 01, 2011 4:54 pm 
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Joined: Jun 14, 2008
Country: USA
State/Province: TX
City: Lancaster
Crankcase reassembled from various angles.









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 Post subject: Re: 250 Engine Tear Down Pictures
PostPosted: Tue Feb 01, 2011 5:01 pm 
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Joined: Jun 14, 2008
Country: USA
State/Province: TX
City: Lancaster
Whatever this stuff is called. The funny star-shaped thing (or Plate Drum Stopper) rotates and may not be in this exact orientation. I include this for other newbies like myself who might get confused. I spent too much time trying to get it just like this pick I took on tear down before realizing the truth.




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 Post subject: Re: 250 Engine Tear Down Pictures
PostPosted: Tue Feb 01, 2011 9:26 pm 
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Joined: May 2, 2009
Country: USA
State/Province: NY
City: &
Beren:

Thank you so much for taking the time to do this for all of us!


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 Post subject: Re: 250 Engine Tear Down Pictures
PostPosted: Wed Feb 02, 2011 2:03 pm 
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Joined: Jun 14, 2008
Country: USA
State/Province: TX
City: Lancaster
Cylinders on:







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 Post subject: Re: 250 Engine Tear Down Pictures
PostPosted: Wed Feb 02, 2011 2:06 pm 
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Joined: Jun 14, 2008
Country: USA
State/Province: TX
City: Lancaster
Cylinder head on:



Cam shaft installed:


Everything lined up correctly:


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 Post subject: Re: 250 Engine Tear Down Pictures
PostPosted: Wed Feb 02, 2011 2:09 pm 
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Joined: Jun 14, 2008
Country: USA
State/Province: TX
City: Lancaster
Camshaft holders installed:



Intake manifold installed.


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 Post subject: Re: 250 Engine Tear Down Pictures
PostPosted: Wed Feb 02, 2011 2:25 pm 
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Joined: Oct 24, 2008
Motorcycle: 2009 Honda Rebel 250
Rebel: 250
Country: USA
State/Province: TX
City: Dallas
Looking great!

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Loud ties save lives


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 Post subject: Re: 250 Engine Tear Down Pictures
PostPosted: Thu Feb 03, 2011 10:22 am 
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Joined: Jun 14, 2008
Country: USA
State/Province: TX
City: Lancaster
Starter gears. Note that the the small gear is mounted on the starter motor that pokes through the metal pacer plate.





Flywheel install. Easier on than off.


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 Post subject: Re: 250 Engine Tear Down Pictures
PostPosted: Thu Feb 03, 2011 10:34 pm 
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Joined: Jun 14, 2008
Country: USA
State/Province: TX
City: Lancaster
On the bike




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