If you are going to tear it down that far a whole bunch more parts should be replaced also and usually a good used motor will cost less than a complete rebuild.

 

That makes me wonder if I want to do all of that... I've been thinking about getting another bike, and I might just end up replacing this one.

Before I do anything though I have to get this stupid flywheel off.

 

I'm really sorry you're so far away. This is the kind of project that at one time called for advice and moral support. At this point it calls for good friends, good beer, and perhaps "what happened in the shop stays in the shop".:whistling: Wish I could be there with you for the rest.

 

There's been plenty of beer and my friends Shelley has been around, which is nice. Actually, I need to go back to the store lol

Sent from Motorcycle.com Free App

 

Sorry this has turned into such a frustrating experience for you. At this point I am just curious as to how that flywheel is stuck on there and WHY would anybody do that?

 

A good used motor is just to cheap to keep investing the time equity you are spending. The only reason I see for continuing this project is to satisfy your curiosity. Start shopping around/watching for a motor deal.

 

I think those are words of wisdom. A new motor would put you back on the street and with a little detailing over the winter you could recoup a higher % of your time/money in the spring if you are still of a mind to do something different than if you continue throwing time and money into what is looking more and more like a lost cause. :frown: :banghead:

That is unless you are interested in a career change to a Rebel mechanic. You obviously have the patience an persistence needed. I admire your tenacity. I'd have got a Lot Bigger Hammer on the job by now.

 

I think we're going to look into cutting the thing off. I'm not sure about the motor thing, I really don't want to give up on my bike, I've gotten used to telling people to stuff it when they say it's too beat up our broken. Also, the cost of buying a different engine and not knowing what's wrong with it... I've bought my share of other people's problems so far, lol

Sent from Motorcycle.com Free App

 

I sold two motors this summer, an 06 with 2200 miles for $200, and an 87 with 5000 miles for $150. Both buyers even called me backed and thanked me again. Funny thing is, I made money on both. IF ya do buy a motor, a compressoin test will tell wonders.

 

I decided to buy a used engine from Pinwall cycle when my original crankshaft broke off just behind the flywheel. (That's why I had a spare flywheel lying around) .
My engine came from a low mileage wreck and they had a video of the engine running in the wrecked frame as well as a shot of the odometer (2500 miles or so) . I have 9000 km on it since then, and it is a great engine. I just did the dawn to dusk rally here in the maritimes with it a couple of weeks ago (720 kms mostly flat out) and it worked great and used no oil that I could detect.
Of course YMMV with a used engine but Pinwall crated it up well in a wooden box and I had a positive experience with them. The engine seems to be very strong.

 

lol I was wondering how you ended up with a spare flywheel, but I thought maybe you had a parts bike laying around.

I've had good experiences with Pinwall, they sold me my "new" brake caliper. I can stop better now. If I buy an engine from them, then they'd be in driving distance, saving the $$$ for shipping.

I think the first step is getting the flywheel off, and then putting the bike back together. Surprisingly the sidecover gasket was still in one piece.

I'll clean the oil screen, see how the engine does after that. Plus, the new piston rings might have something to do with the shavings on there.

I might be buying a friend's Savage, not 100% sure yet.

I've got a ticking sound to deal with, too, which is probably (maybe?) not related to the oil seal, but I think it might have been the valves being upset about not having oil anymore when I dumped the oil everywhere.


Can I throw any year engine in there?

 

Trying a die grinder next.... wish me luck!

Sent from Motorcycle.com Free App

 

Good luck wished!!

 

I'm pretty anxious to see what's under that flywheel.

 

Best of luck!
__________________

 

:thumb::thumb::thumb:You can do it - YouTube

 

Can't wait to see what you find. Not enough room for Jimmy Hoffa.:nonono:

 

It has begun!

Sent from Motorcycle.com Free App

 

Best of luck. Keep the pictures coming. I want to see all the gory details. This could turn into a learning event.

 

Made it through! On a beer/let the air compressor cool down break. I estimate it'll be maybe another hour and I'll have a rectangular chunk out that I can access the hub with. Then this *#$@°¥ is going down!

Sent from Motorcycle.com Free App

 

Look! I feel optimistic!

Sent from Motorcycle.com Free App

 

I don't know the nature of your cutting wheel. Depending on what it is you might make quicker progress if you sprayed a light oil on it while you are cutting.

Anyone else ideas?

 

I hate to say it, but I think you voided your warranty.

 

3" cutting disk on a die grinder, powered by a please-don't-call-the-cops-on-me air compressor (it's a shade before midnight). Dunno about oil, but it's going decently I think.

Sent from Motorcycle.com Free App

 

Crap, you think I can cover this up and they won't notice at the shop?

Sent from Motorcycle.com Free App

 

Hanging it up for the night. It's 2:30, probably too late to run the air compressor... That and I'm tired of grinding away. I think I'm going to cut off another slice on the other side and do the same thing.

 

Charlie..you're a trip man... You're a great read in persistance.

I bought an 86 250 motor with 16,xxx on it running for $120 (we started at $180). Runs great but the guy wouldn't throw in the starter. I sold the carb and intake for $50. net cost... $70 bucks.

I have the kick start assembly, all new seals, and a belt drive assembly for it. I am out about $260. I am going to rebuild the clutch also. I plan on polishing it up and sticking it into something down the road. I'd like to get my hands on a dual carb stock air box from down under and go that route. We'll see

With due diligence and some cash stashed, you have to be prepared to buy when a good deal presents itself. I didn't need a motor. It was just too good a price to pass on and it ran fine. Even before hearing it run, I did a compression test. The guy thought I was being a jerk because he was selling it so cheap. I ain't no fool. It will tell you most of the story on a used piece without going crazy. Peace of mind.

 

Charlie..you're a trip man... You're a great read in persistance.

Thanks, man. I guess I'm just not that good at giving up...else this bike woulda been gone a long time ago!

Charlie, if you are reading this you are not cutting that nut off :greetings10: git back to work!

Yeah Charlie. That thing's not gonna cut itself!

Yes, yes, yes, but I need to eat something first! And after I cut on it for a while I'll be able to take that 3 jaw puller back (and get my $$ back) and get some more coffee, since this is the last of it, and that's unacceptable!

 

Mojo, where'd you find the belt and sprocket set up?

 

eBay
I think I paid about 60-70 dollars for it. I put "1982 cm250 belt drive" in my saved searches and waited for one to pop up. Surprisingly it came with the belt. I want to cut the belt and mount the pulley's to get an accurate belt length. I am certain I can find a belt to fit the Rebel with the right info. But that belt is worth some coin and I'm not sure cutting it is a good idea. Damned if you do, damned if you don't kind of thing.

 

Charlie, if you are reading this you are not cutting that nut off :greetings10: git back to work!