Posts
6154
Joined
1/31/2018
Location
Mansfield, OH
US
Edited Date/Time
7/14/2020 7:11am
Had a post a while ago about this 09 kx250f not starting. Has spark, getting gas, leakdown and comp tests passed. It only afterfires out the exhaust every few kicks. Bike started 1st kick and ran great before teardown. I thought there was a CDI issue but apparently not.
Timing looks like it should work for me. The intake cam gear looks almost like it slipped though. Can some experienced eyes take a look please? Im about to sledge hammer the crank cases.
Timing looks like it should work for me. The intake cam gear looks almost like it slipped though. Can some experienced eyes take a look please? Im about to sledge hammer the crank cases.
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The intake cam does have a dot. It is hidden by the head. How would i go about degreeing the cam?
Dot prob shouldn't be hidden and even at edge of cyl
Lobes should prob be flat
woodruff key on flywheel broken timing off
The sad thing is this bike was such a reliable starting bike before. Probably the easiest starting bike ive ever seen.
Ill pull the flywheel and verify its good. I put it together correctly, but ill verify anyway. I may also pull the cylinder and just verify the entire top end as well.
Bringing up an old post, what was the outcome with this issue?
Im experiencing the same thing on a customers 2009. Bike ran great till he locked up the bottom end, easiest starting bike ive ever seen. We replaced bottom end with wiseco and top end together, cant get this dang thing started unless your bump starting it and even then it will not idle at all. verified good compression, nice bright spark, clean carb, even starting fluid doesnt help. i thew a dial indicator on the piston and physically set engine to TDC, flywheel timing marks are NOT aligned with timing cover- about 1 tooth off. re-timed engine to physical tdc and not flywheel mark and bike started first kick but would not rev out at all. (probably because pick-up timing is off now). ive worked on this bike for years, adjusted valves and re timed countless times in the past, never had this issue. only thing i can think is the wiseco crank has to be keyed wrong? were reusing the original flywheel so no variance there. searching this issue there seems to be ALOT of concerns with Kawasaki timing marks. ive contacted wiseco and theyve got me sending the crank back for inspection. This crank has since been discontinued from wiseco, wonder what the reasoning was. looks like the 2008 timing cover had the timing cover mark in a different location then the 2009, maybe i got a 2008? Ive got so much money and labor wasted in this bike, i could have bought him another 2009 by now.
Pit Row
Are the cams original ?
if so ,
Cam gear could have slipped on cam
Pro circuit cams. I know that's an issue on these kx's. As far as I can tell they're still spot on. Comparing the lobes to other pictures and forums , I see no degree change.
but I'll tell you after the issues with this bike, every KX I get in the shop is getting a centerpunch between Cam and gear to visually monitor every valve adjustment.
Check orientation of tip over sensors, possibly when taken apart it was installed upside down
Don't believe there is a tip over sensor on the 2009 model is there? The 09's are still carbureted and I've got nice bright spark.
Verified neutral timing switch works as well. But still, physical tdc does not line up with flywheel marks. Anyway to get a diagram of woodruff key vs Rod big end before I send it back?
I would be very suspect of those cams if they were in the bike when it grenaded
I’ve had this problem myself is why I bring it up
Timing “ appears “ correct but isn’t
Hope you get this nailed down !
I'll try to get info out of procircuit, hopefully I can get a degree measurement - probably "confidential" information though.
eye balling it to pro-circuits "actual picture" exhaust looks legit. And when assembled eyeballing lobes looks legit.
dang dude, i grew up in shitcrest - small world lol
Lol
i would send them into PC and let them inspect them
I had a hotcam that the gear spun on
sent it in to them so they could inspect it and sure enough the gear had spun on the cam
they sent me a new one
Been through hell on this 09 KX250F, so I figured id share the conclusion for anyone else suffering from headaches.
Pro Circuit doesn't offer these cams any more, they've ditched all their jigs so there's no real way to determine if the cams have slipped. They said the only way to know is to "buy some factory cams and see if it starts with those" 🙄🙄
Wiseco refused to tell me it was off but finally accepted my return and my supplier refunded me money. Bought a HotRods crank this time and through the pc cams back in for the hell of it, nothing else changed. Starts first kick just like she should. Such a relief I can finally get this bike out the door, but of course not before I punch alignment marks on the cams.
Every Local moto machine shop or moto mechanic I talk to claims they refuse to use wiseco because they've had so many issues. That's crazy to me. Lesson Learned, TRUST NO ONE ASSUME NOTHING. Double check that tdc mark during install, takes 60 seconds and a couple degrees off kills you. KEEP YOUR OLD PARTS TILL THE FAT LADIES SINGING!
Just another reason to never buy a Wiseco crank.
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