Lost and confused - Honda Rebel Forum
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post #1 of 10 Old 05-20-2020, 09:29 PM Thread Starter
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Lost and confused

I haven't ridden in almost 30 years and my craving came back so i bought a 2003 rebel 250cmx from a guy that has had it sitting in his garage for 3 years unstarted. I bought a new battery, plugs and drained and changed the oil. It fired up and i was in heaven for a couple days till i noticed a serious oil leak. I figured it was the seal behind the flywheel. I took it apart and the seal was fine but i found a hole in the crank case that you could put your finger in. I love the bike so i bought a new crankcase. Here's my problem. I have no idea how to pull the motor or swap the crank case. Anyone please help me out. What do i do?
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post #2 of 10 Old 05-20-2020, 09:54 PM
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Welcome. If you have the tools, desire and a service manual (I recommend the Honda manual), doing what you describe will involve a lot of time, but is certainly doable. The manual will guide you step-by-step, with pictures, and folks here are very willing to help. Another option would be to buy a low mileage used engine on ebay and sell the undamaged parts on the existing engine.

Where are you located? There may be a forum member nearby that would be willing to assist.
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Keepin' all the left over parts. Gonna use 'em to build another bike!

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
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post #3 of 10 Old 05-21-2020, 02:18 PM
 
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Can we get a picture of the hole in question? Behind that left side cover isn't intended to be oil-tight, there are a couple places oil can gather once it gets over there past a seal which would not be indicative of a problem. Want to make sure the hole in question is actually not one that is supposed to be there. Sometimes the starter sprocket seal fails too, so it could be that and not the flywheel seal actually leaking.

2008 Rebel 250, 2014 Street Triple, 2012 Voyager 1700, 2014 FLD Switchback, 2017 Guzzi V9, 2017 Concours 14
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post #4 of 10 Old 05-22-2020, 10:08 PM Thread Starter
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This is pbernesser. Here are the pieces that were laying inside the cavity where the hole is. The arrow in the picture shows where the hole is inside
Attached Images
File Type: jpg imagejpeg_0_2_1590199349790.jpg (261.0 KB, 5 views)
File Type: jpg IMG_03861_2_1590199401690.jpg (103.7 KB, 6 views)
File Type: jpg 20200423_174909_HDR_1590199473303.jpg (173.9 KB, 4 views)
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post #5 of 10 Old 05-22-2020, 10:19 PM Thread Starter
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Quote:
Originally Posted by Lexiyntax View Post
Can we get a picture of the hole in question? Behind that left side cover isn't intended to be oil-tight, there are a couple places oil can gather once it gets over there past a seal which would not be indicative of a problem. Want to make sure the hole in question is actually not one that is supposed to be there. Sometimes the starter sprocket seal fails too, so it could be that and not the flywheel seal actually leaking.
here are pics of the pieces i found laying just below the hole and the arrow points just below the hole
Attached Images
File Type: jpg IMG_03861_2_1590199955460.jpg (103.7 KB, 7 views)
File Type: jpg imagejpeg_0_2_1590199981794.jpg (261.0 KB, 7 views)
File Type: jpg 20200423_174909_HDR_1590200158253.jpg (173.9 KB, 5 views)
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post #6 of 10 Old 05-23-2020, 08:41 AM
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Not good! A new crankcase will be needed as a minimum, and hard to tell if there is secondary damage. It's probably rebuildable, but if I were you, I'd be looking for a replacement engine.

Keepin' all the left over parts. Gonna use 'em to build another bike!

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
Putting your bike year and model in your signature helps others help you!
Here's how: https://www.hondarebelforum.com/f19/...re-121087.html
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post #7 of 10 Old 05-23-2020, 11:52 AM
 
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Wow, thanks for the pics. I haven't seen damage like this on a Rebel before. That bolt has a weird damage pattern, it looks like it was ground off smooth through its mounting point before it failed.

2008 Rebel 250, 2014 Street Triple, 2012 Voyager 1700, 2014 FLD Switchback, 2017 Guzzi V9, 2017 Concours 14
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post #8 of 10 Old 05-23-2020, 03:18 PM
 
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I can't add anything to the knowledge end of things but want to welcome you back to riding and from what you have said so far, I believe you will be successful in fixing the existing motor or installing a replacement...

Grace + Peace, Bob
2007 Honda Rebel 250 - Red. Stock.
I'm 84 and still riding
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post #9 of 10 Old 05-24-2020, 02:14 AM
 
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Garage
Most likely, it threw a chain through it.

Trust me, I'm an Engineer!
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post #10 of 10 Old 05-24-2020, 02:20 AM
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Can you measure the bolt in mm both diameter and length and give us the measurement?
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