cam shaft???????????
dontcha mean crank?

 

cam, crank, bumpy hunk of steel ...

Corrected. Thanks!

 

spinning metal that does voodoo and makes your engine go

 

FWIW if you're using a PC, you can open pictures in Paint and resize them to a smaller size, around 800px is good for posting. You can crop them too. Works well. I use it both on forums and in teaching web design at school. Makes it easier to get them loaded.

 

klx678,
Thanks! This is also accomplished by editing the source through the native "advanced" editing page. Done!

 

Problem - I don't have the crankshaft installation jig prescribed in the manual so I need to set the crank manually. As a first attempt I set the rod centered in the cylinder opening. This results in the crank to balancer shaft having this relation to each other:




Unfortunately, I couldn't get a photo that would show the proper relationship/position of the crankshaft.
Does anyone know a way to set the proper position minus the jig?

Thanks!

 

looks to me like the balancer shaft bearing isn't in the case all the way... but that could be be the pic. if the crank is centered, thats what you want

 

I have never done a KLX250. Once you get it clocked correctly post some pics. Nice to have this info available. And like I said before, everybody loves threads with lots if pictures!

Your doing a pretty thorough job on this rebuild, dam fine job I must say!

 

Thanks! I'm always benefiting from these forums. Its about time I contribute a little.

I discovered two things about the problem at hand:

1. The LH bearing seats fully against the crankshaft
2. The balancer shaft gear needed to be flipped-over to properly mesh with the crankshaft gear

I just need to double check that all washers and shims are located correctly and then the case halves can be joined.



Punch holes aligned

Amazingly close 5th gear clearance to crankshaft.

I didn't find any information but I think I understand this strange two-piece, spring-loaded balancer shaft gear. This design will provide constant positive force against the crankshaft gear and prevent chattering.

 

Good to see that you noticed the issue. Pics in the service manual show the gears installed like you have in the post above.