TS250 5 SPEED

[Andy_C]

Ok so the bearings are out of the case - got the case really hot and they drifted out fairly easily.

I took a good look at the gearbox beariing and flushed it out with some WD40, perhaps something got in there while I was dismantling it, but it felt perfeclty smooth.

So I heated the bearings with my hot air gun and they dropped over the crank and gearbox shafts really easily, and tapped them home for good measure.

All set for re assembly now once I have the little sealing grommet that goes between the cases - hopefully next week.

When I re assemble I shall make sure that I get the case hotter than I did when dismantling so that it will easily go over the bearings.

The main bearing did have a couple of small dabs of what looked like loctite or similar on it, and did not come out as easily as the gearbox bearing.

I am optimistic that the lack of any sign of sealant on the case was the cause of the problem, and that re assembly will be smooth providing I get enough heat into the cases.

Starting to feel a bit better about this bike now, but only time will tell.

[Blurredman]

Good good good!


Now I seem to recall I said something about the small black disc in a previous post (page 1).



How was the condition of yours... if you had one at all!?

[Andy_C]

The black disc was there but looked like it could have been overlapping onto the joint faces, and may have been holding the cases apart a little.

As Puffs pointed out in a previous post I cant see how if not fitted or badly fitted that it could cause gearbox oil to get into the crankcase.

Not sure of the purpose of the disc - it seems to separate the 2 sides of the crankcase, perhaps someone with greater knowledge would like to comment.

[Puffs]

Removed

[Andy_C]

Latest update.

Engine re assembled / sealed.

No problems fitting the case, this time I heated it with my hot air gun until it was hot enough to boil spit - took quite a time, but the case dropped nicely over the bearings and just needed a few gentle taps with a rubber mallet to make the cases mate.

Engine now back in frame, just have to fit dynamo / points etc, exhaust, carb and clutch cable, should be ready to fire up at the weekend.

Lets hope all this effort has solved the problem.

[Blurredman]

My fingers are crossed for you Andy!

Did you use a gasket between the two crankcase halfs or rtv?

[Andy_C]

"Did you use a gasket between the two crankcase halfs or rtv?"

I used some stuff called "Wellseal" which is a non setting jointing compound.

I have every confidence in this stuff as I have used it on bikes for as long as I can remember.

You don't use a gasket between the crankcase half's.

[Blurredman]

"Did you use a gasket between the two crankcase halfs or rtv?"

I used some stuff called "Wellseal" which is a non setting jointing compound.

I have every confidence in this stuff as I have used it on bikes for as long as I can remember.

You don't use a gasket between the crankcase half's.

I'll have to look into that stuff.


Yes I'm aware that they didn't come with a gasketfrom the factory, but these days 'gasket kits' come with a gasket for the two crankcase halfs. I have used said gasket in 2x etz250 engines without problems (that only 5k and 6k miles use each piece forsees), but I won't be using the supplied gasket when I put my ES250 engine back together. I'll be using some sort of sealing compound like you..

[Puffs]

Or join the Loctite gang...

[Andy_C]

That's me done.

It wont start, all it will do is pop / bang.

Timing is spot on, carb settings correct, tried different combinations of coils and spark plugs, silencer is not blocked, there is nothing else.

This thing is jinxed.

As I say that's me done, no more EMzs for me untill I get myself a really good ETZ 301

It will be appearing on E-Bay soon as a non runner and at a bargain price.

Over and out.............for now.

[Puffs]

I don't believe in 'jinxed' but you gave it your best... Don't know what to say.

[Andy_C]

Puffs - now that I have gathered my thoughts, and got over the frustration, I have decided to put the bike to one side and concentrate on some other stuff.

I did find out yesterday that spanners bounce pretty well when you throw them at the garage wall !!!

At the end of the day, it is just a machine, and can be fixed.

I just have not found out what needs fixing.......yet.

So I shall probably go quiet for a while, but will revive this thread once I have success to report - it will happen.......hopefully.

Signing off for now.

[Andy_C]

Time for an update - already.

I have been over the timimg and ignition with a fine tooth comb / checked and re checked, gap and timing are spot on, all connections good, tried 2 different coils, 3 different plugs, 2 plug caps and 2 leads. I also returned the ignition to the factory arrangement i.e. took out the "points assist" module. Also made sure that the battery was well charged.

Under all permuations of plugs / coils / caps etc the result was the same, it would run for about 10 seconds, and then die due to a very wet plug.

This has convinced me that it is either carburation releated (despite new jets & fuel level being correct), or possible that the cases have a crack that I did not see that is allowing oil to be drawn in from the gearbox. I have tried it without the filter and I get exactly the same results - an oiled plug, so not the filter.

Someone is going to lend me a good known to be OK carburettor which I am going to try, but before I do that I am going to walk away from it for another week or so.

If it still has the same problem with the known to be Ok carb fitted then it has to be drawing oil in from the gearbox, and if that is the case, I will probably put it up on E-Bay as a non runner, at this point however I remain optimistic.........but think I have had that optimism once before

[Puffs]

Removed

[Blurredman]

ES250's are capable of running with broken (and leaking) main seals. I feel confident in saying that maybe it isn't the gearbox oil being burnt.