[Exmoz]

1. Could the damage caused to the black plastic be related to the issues I am facing?
(The mechanic claims he did not cause that damage, but I have photos of before I took in the bike in and after, as they damaged my front break fluid glass thing in December).

Hi there, this has been concluded to be completely unrelated.
The engine simply reached end of life due to excessive use, 66k km done, no idea how many owners the bike had.

 

[TheoR]

66k km is not that high a mileage on these bikes. I suspect something was done to the bike, resulting in your engine seizing. The fact that the external component, although unrelated to the engine, was damaged leads me to further think that something happened.

From the pictures you posted, the cylinder wall looks to be scored. Perhaps, the bike was serviced and the oil filter installed in a reversed manner. Or, perhaps, the engine was run dry accidentally?

Obviously, it's all conjecture at this time.

 

[Exmoz]

Thanks for the input @TheoR
The filter seems to have been installed correctly as seen in one of the images.
Also cross checked it the other day with Tamir's guide.

The left side of the bike got dropped that's for sure, there is a big round thing on the left side casing that's supposed to be silver, but it's black, so they resprayed for sure.

Previous owner messed up the wiring, had led strip inside and no working headlight!

The air filter cover was removed off the bike when I got it, that little black lid.
Ordered and installed one about 3000km ago, motorcycle also ran in cold dry climate it's whole life, then moved to the coastal area and used in 30-40degrees.

 

[Exmoz]

Parts Ordered and recieved so far:

DID Gold Xring chain with new sprockets OEM standard size.
Main Crankshaft Bearing - Blue
Piston Rebuild kit - with cylinder included
Bunch of gaskets and O rings
Crankshaft replacement kit
Spark Plug - Although current one only has 2000km done on it.

---

Second order (mechanic needed more-parts) :

Main Crankshaft Bearing - Blue
Night Eye LED
Handlebar ends
Handlebar grips
Oil filter and Gasket for service after engine is broken in (1000km)
Neck Steering Bearings - they are due for replacement, might as well do now.

 

[Tamir]

66k km is not that high a mileage on these bikes. I suspect something was done to the bike, resulting in your engine seizing. The fact that the external component, although unrelated to the engine, was damaged leads me to further think that something happened.

From the pictures you posted, the cylinder wall looks to be scored. Perhaps, the bike was serviced and the oil filter installed in a reversed manner. Or, perhaps, the engine was run dry accidentally?

Obviously, it's all conjecture at this time.

Your hypothesis makes sense. I bought a motorcycle that was neglected. When I bought it, it looked good, it drove well, but I knew I was buying a motorcycle that had been neglected.

Several years have passed since then, and since the
I'm still chasing a fault, I started with what was easy and cheap to fix, and today the problem still exists.

My problem: The engine has difficulty starting when cold. Below 25 degrees I starting it with a rotation of one degree in the throttle. I bought the motorcycle in the summer and I could feel this problem, then winter came...
Now I only have the major treatment left, apparently (because this measurement is not accurate), I have a compression drop when the engine is cold, and when the metals expand from the heat, everything works normally. There is no smoke from the exhaust and no other evidence of oil leaking into the engine, but that is currently the main suspicion I still have: a compression drop.

My motorcycle has already traveled over 70,000 km, and the engine works smoothly and beautifully, except for the problem I mentioned.

I think I received the motorcycle after an event of overheating as a result of an oil leak from the coolant pump oil seal. A 250 engine that working at high rpm doesn't have much to do to destroy it, 70,000 km is very respectable. Maybe I did treatment to the upper engine, to improve the compression? But maybe not! Why to touch it as long as there is no oil leakage. Nothing will happen if at low temperatures my engine is starting with the addition of a tiny turn in the throttle

 

[Exmoz]

Update!
All parts has been delivered to mechanic, waiting for them to complete the rebuild.
It has been 3 weeks so I'm hoping they have not faced any issues.

Too scared to call and find out!
(don't want any more expenses)

End of day, I'm still feeling good about spending almost 1200usd thus far.

I just wish it could come to an end and me back on the saddle!

 

[Tamir]

1200usd

In economic terms that I know, this is considered a reasonable total financial expenditure. Everything is now about the quality of the work, and later the quality of the first run.
Let's hope for the best👍

 

[Exmoz]

@Tamir
Do you know what tool is needed for removing crankshaft bearings?

My mechanic says they can't rebuild because they need the tool!

This person in below thread made one but theres no pictures

Crankshaft bearing removal and installation

Hello, SO, I have my 2011 CBR250r engine apart and it looks like the main crankshaft bearings are toast. This engine rebuild was the result of an engine stop due to an oil filter put in backwards (yes, this was my bad). These bearings are plate type parts (each bearing is made up of two...

www.cbr250.net

 

[Tamir]

@Tamir
Do you know what tool is needed for removing crankshaft bearings?

My mechanic says they can't rebuild because they need the tool!

This person in below thread made one but theres no pictures

Crankshaft bearing removal and installation

Hello, SO, I have my 2011 CBR250r engine apart and it looks like the main crankshaft bearings are toast. This engine rebuild was the result of an engine stop due to an oil filter put in backwards (yes, this was my bad). These bearings are plate type parts (each bearing is made up of two...

www.cbr250.net

It is a sliding bearing that is made of two halves, so without proper support there is a good chance of destroying the bracket, or the bearings, or the case, or all both.
The process should be carried out very carefully, you will find full instructions in the motorcycle's maintenance book, page 12-10.

I've taken for you a pic of the sketch and number of the main tool,
but it's definitely not enough.

 

[Exmoz]

Thanks @Tamir that is what I need to continue!
Regretting my decision now, I should have ordered the engine case from Zuber with all my other parts.
With that casing it is pre-installed!

Maybe I must just order it and get it done as my mechanic already delayed 3weeks trying to figure this out.

 

[Tamir]

Thanks @Tamir that is what I need to continue!
Regretting my decision now, I should have ordered the engine case from Zuber with all my other parts.
With that casing it is pre-installed!

Maybe I must just order it and get it done as my mechanic already delayed 3weeks trying to figure this out.

This is very strange, professional mechanics always have methods and patents.
Maybe take this particular assembly to a mechanic who knows that job?

 

[Exmoz]

The bike is on the bench at mechanic since Monday and hoping to have her rebuilt by end of next week.

Happy to update that all parts are received, my mechanic failed to notice that the one side of the Crank Casing is code BLACK bearing, so I had to re-order them from RevZilla for quickest transport to me.

The majority of my parts has been ordered via Zuber from India - Amazing guy!
Ordered a few odds and ends from RevZilla.

This bike is going to be almost fully restored to OEM condition when completed.

 

[Exmoz]

Happy to update the motorcycle is restored to factory condition.
Gearbox smoother than ever and the fuel economy is better.

Lower range revs use to feel dead and sluggish, now it is crispy clear and smooth.

Less engine vibration, less engine noise. Overall I think it's a fantastic job done.

The NightEye LED makes a humongous difference, worth every cent!

280km (refueled at 200km) done so far, taking her back in at 500km.

 

[Donovan1]

UPDATE:
Crankshaft and Piston rebuild kit is required.
With all the needed gaskets.
Local mechanic asking 1500usd to repair.

Sourcing parts from an alternative supplier to see if I can save costs.

It is a dark time, this cbr is costing me the same price as what I paid now.
But in all honesty, it's saves so much fuel and drives so **** good I have to restore it.

@Tamir unfortunately I did not notice any engine noise, but my hearing is not good.
The mechanic noted that the engine noise is odd on the picture of quote I attached about fork seals that were done.

Did you manage to come right with rebuilding the engine? I am also based in South Africa.

 

[Exmoz]

Did you manage to come right with rebuilding the engine? I am also based in South Africa.

Yessir, fully restored and operational check the post above yours also.

Can help you get parts if you need, it's kak expensive (cheaper than local) but worth it if you love your cbr250r.
Able to get a whole new cylinder and piston, something wings honda doesn't supply at all they advise to rehone with Nikasil claiming the cylinders aren't available.

I'm able to get any part directly from honda factory in India

 

[Tamir]

Able to get a whole new cylinder and piston, something wings honda doesn't supply at all they advise to rehone with Nikasil claiming the cylinders aren't available.

Our cylinder is a standard and generic STEEL sleeve. If the cylinder is in reasonable condition, it can certainly be renewed with the Honnig process, and NEW piston and rings.
Sometimes cleaning the piston, and especially cleaning soot from the grooves of the rings in the piston, then maybe you can also leave the piston and replace only the rings.

And this too, I saw on the Aliexpress website that you can buy a oversize piston.

It all depends on the condition of the parts and the available budget for the repair.

Our cylinder is not made of aluminum, and the claim for Nikasil coating is only true for cylinder made of aluminum, it not relevant to our STEEL cylinder.

 

[Exmoz]

Hi @Tamir
For clarity, I'm not talking about Aliexpress, I'm talking about our savior Zuber in India who works at Honda factory and helps us to get original parts.

I remember your post about what sleeve we have, the mechanic told me nikaseal is what they're going to do to repair it, but the cost was R8500 just for the labour and nikaseal.
Brand new cylinder and piston kit (original size) cost only R4000, so it's a no brained to replace rather than to rehone.

 

[Tamir]

Hi @Tamir
... the mechanic told me nikaseal is what they're going to do to repair it, but the cost was R8500 just for the labour and nikaseal.

My starting point, always, is that the professional mechanic, the one who also sees the motorcycle, and doesn't just read about it on the forum, is the expert in determining what needs to be done and how, and that's on the condition that you trust him, because, like you, I don't know him either.

Our motorcycle, our model, CBR250R 2011-2013, does NOT have an aluminum cylinder sleeve. The mentioned coating "nikaseal" is only possible on cylinders that are made of aluminum. Our cylinder is made of steel and does not receive any kind of coating like "nikaseal".
Our cylinder sleeve:

• is bare steel, wet it, and it will immediately catch rust,
• bring a magnet near it, and it will be attracted to it,

this is because it is a steel rich in carbon, and NOT an aluminum compound.

Therefore, if our cylinder is in reasonable condition, it can be renewed in a cheap and simple honing process.
And it's true, and It is also not really clear what the reason, that Honda doesn't sell oversize pistons. That's why I mentioned AliExpress, which I understand they do sell. And I added that if the piston is in reasonable condition,

• Honnig the USED cylinder
• +deep cleaning of the USED piston
• + NEW set rings,

this is also a cheap option for repair, for those who are really short in terms of budget.

I don't recommend doing this or that, I'm just sharing the knowledge I have.
Sorry if I wasn't clear. Everything is fine.