Honda Rebel Forum banner
  • Hey everyone! Enter your ride HERE to be a part of November's Ride of the Month Challenge!
1 - 20 of 26 Posts

·
Registered
1989/2005 Honda Rebel 250 and 1986 Honda Rebel 250
Joined
·
12 Posts
Discussion Starter · #1 ·
I have to replace the shift forks on my Rebel 250. I'm having a heck of a time getting the flywheel off. No, I don't have a puller. Any advice please!!!
 

·
Super Moderator
1987 CMX250C AC
Joined
·
2,737 Posts
all you need is a 16x1.5mm bolt threaded into center of flywheel pressing against the crankshaft..
as you tighten it will push the flywheel off.. few raps on bolt head will help facilitate removal..
 

·
Premium Member
85 CMX 250C, 82 GW Remember that you are invisible, treat all others accordingly. Avoids Road RAGE!
Joined
·
2,113 Posts
I see that SoakedKarma already answered your question.
I just wanted to say welcome to the forum! I like the biker boots in your picture. I used to have a few pair like those, but they were used for utiliy pole climbing.
 

·
Registered
1989/2005 Honda Rebel 250 and 1986 Honda Rebel 250
Joined
·
12 Posts
Discussion Starter · #4 ·
all you need is a 16x1.5mm bolt threaded into center of flywheel pressing against the crankshaft..
as you tighten it will push the flywheel off.. few raps on bolt head will help facilitate removal..
I got the bolt today. Will let you know how it goes. Thank you!
 

·
Registered
1989/2005 Honda Rebel 250 and 1986 Honda Rebel 250
Joined
·
12 Posts
Discussion Starter · #5 ·
I see that SoakedKarma already answered your question.
I just wanted to say welcome to the forum! I like the biker boots in your picture. I used to have a few pair like those, but they were used for utiliy pole climbing.
They are lineman's boots actually. I wear em all the time. Carolina brand. They make a good long lastin boot. A lot of ironworkers I know get them resoled with a flatter sole for workin on the steel. Thank you for your reply.
 

·
Registered
05 Honda CMX250C | 93 Kawi VN750
Joined
·
56 Posts
A strap wrench works wonders for holding the flywheel. I got mine for $20, and I believe it's what the manual calls for, too, though I don't have it handy at the moment to confirm. You can get away with using the transmission to lock the flywheel in place (keeping the bike in gear), but that's some strain I wouldn't risk.
 

·
Super Moderator
1987 CMX250C AC
Joined
·
2,737 Posts
Pullers don't cost much
Honda OE flywheel/rotor puller part # 07733-0020001 as noted in Rebel shop manual is 4 threaded shafts in sizes 16mm, 18mm, 20mm, 22mm... The Rebel utilizes the 16mm thus a 16x1.5mm bolt is all that is needed and costs much less than any puller,, Use of multi arm gear puller on a flywheel/rotor can cause irreparable damage by bending the metal casing..
Font Composite material Fashion accessory Metal Steel

Jaw Gesture Elbow Font Knee
 
  • Like
Reactions: MissPossum

·
Registered
1989/2005 Honda Rebel 250 and 1986 Honda Rebel 250
Joined
·
12 Posts
Discussion Starter · #10 ·
Well, hmmmph! I used a nut as a spacer then tapped the bolt and the flywheel came right off. Thanks!

Now my new dilemma: I have split the case and there is no broken shift fork. There is nothing broken and all gears look fine to me. Any idea what could be the cause of the bike having no gears? Every gear is as though it's neutral.
 

·
Premium Member
85 CMX 250C, 82 GW Remember that you are invisible, treat all others accordingly. Avoids Road RAGE!
Joined
·
2,113 Posts
I know that this might sound like a silly question, but have you checked the clutch? If it is shot, or not adjusted correctly, that's what'll happen.
 

·
Registered
1989/2005 Honda Rebel 250 and 1986 Honda Rebel 250
Joined
·
12 Posts
Discussion Starter · #12 ·
I know that this might sound like a silly question, but have you checked the clutch? If it is shot, or not adjusted correctly, that's what'll happen.
I installed new clutch first, and still got the same result.
 

·
Premium Member
85 CMX 250C, 82 GW Remember that you are invisible, treat all others accordingly. Avoids Road RAGE!
Joined
·
2,113 Posts
How long have you had the Rebel? Did it ever work for you?
 

·
Premium Member
85 CMX 250C, 82 GW Remember that you are invisible, treat all others accordingly. Avoids Road RAGE!
Joined
·
2,113 Posts
I know this is very simplistic, but please bear with me. The linkage can also cause this problem if it isn't in the right position. Several have had this situation with 1 or all gears not working correctly.
I always try the simple things 1st, because if it fixes it, no more cost, effort, or time is wasted. I've chased "major problems" before, to kick myself later for not trying the easy ones, 'Which ended up being the problem in the 1st place'.
 

·
Registered
1989/2005 Honda Rebel 250 and 1986 Honda Rebel 250
Joined
·
12 Posts
Discussion Starter · #15 ·
It was workin fine. I've had it 3 years and ride almost every day. I started it, took off in 1st, shifted to 2nd...nothin. No warning signs or noises. I checked linkage more than once after finding a diagram on this forum. I've been trying to solve the problem almost 4 months now.
 

·
Registered
1989/2005 Honda Rebel 250 and 1986 Honda Rebel 250
Joined
·
12 Posts
Discussion Starter · #16 ·
I'm going to put her back together and start all over I reckon!
 

·
Registered
05 Honda CMX250C | 93 Kawi VN750
Joined
·
56 Posts
That's real weird. Not much to go wrong if the transmission is intact with a new clutch pack. At this point, I'd try simple checks again, for sanity. With the engine off and rear jacked up, are you hearing positive clicks when shifting with the lever? If so, what happens if you manually push the clutch plates together (no springs installed, be one with the clutch), and spin the crankshaft? If they're slipping, it's got to be the clutch. If they're biting, spin the rear wheel to 100% be sure if that also spins the countershaft.
 

·
Super Moderator
1987 CMX250C AC
Joined
·
2,737 Posts
One thing comes to mind, missing gearshift arm spring which is known to fall off on occasion..
Video is cued up to informative point
Hand tool Tool Bicycle part Metal Fashion accessory
 
  • Like
Reactions: Yaatri and Emil
1 - 20 of 26 Posts
Top