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CRF450 not starting after I took it appart (imagine that)

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Posted by: Indy---------------------

Howdy all,

CRF450R
2004


I just finished putting my bike together and it will fire but will not run. I pulled the engine apart to look at the transmission (changed out some parts) and just finished putting it all together. I re-checked the cam timing and it appears fine, I then triple checked it to confirm it is proper. I have fresh gas and a new plug.

Timing: Lined up the arrow on the cam holder to the gear flat mark; cam is in the up position pointing toward the rear of the bike. I lined this up after having the primary gear mark lined up with the index mark on the right crankcase cover. I had a indicator to prove that the piston is at TDC.....As per my manual.


Is it possible that the ignition timing is out, sparking after TDC on the compression stroke?

Any other ideas? Let me know if you have any ideas or if you require more information.

Indy.


Posted by: _JOE_---------------------

Did you look under the ignition side cover to ensure everything is lined up there?


Posted by: Indy---------------------

I pulled that side cover, I have not adjusted anything other than taking off the flywheel when I disassembled it. It is lined up with a woodruff key, so it cannot be miss-aligned?


Posted by: IndyMX---------------------

You need to pull the plug out of the side of the ignition cover, be careful when you put it back in, it will snap in two if you over torque it. (Guess how I know this)

Line up the timing mark on the flywheel with the mark on the cover, plus have the mark on the crank side lined up..

Then look at the mark on the cam. This will tell you if you are a tooth or so off.

1 tooth off will make it a real ******* to get it running. (Again, wonder how I found out)

If everything lines up, you have fuel, clean air filter, good plug and all that, it should start and run.


Posted by: nikki---------------------

Quote:
Originally Posted by IndyMX
You need to pull the plug out of the side of the ignition cover, be careful when you put it back in, it will snap in two if you over torque it. (Guess how I know this)


Don't feel bad, you're not alone. Red's snapped one of those too.


Another thing to check is when the bike is at TDC, are you checking all of the valve clearances again? Once on a YZ 250F rebuild we had a shim that wasn't fully seated in its groove that threw us for a loop for a while, until we pulled out the feeler guages and noticed there was no clearance on that valve!


Posted by: Indy---------------------

So.....I checked the valve clearance, they are within spec.
I have been following the manual but it seems to be missing some pages. I ripped all the other languages off of the back leaving the English section. (Really regretting that)

The mark on the flywheel (electrical side) and the mark on the primary drive gear (clutch side) will not line up at the same time on their covers marks at TDC. They are out a few degrees.

Did I make mistake at assembly?

There are two marks on the flywheel, they are close together <1/8" apart which one is supposed to align with the cover?

Is there an on-line manual?


Indy.

Thanks for the help.


Posted by: Ol'89r---------------------

Quote:
Originally Posted by Indy
The mark on the flywheel (electrical side) and the mark on the primary drive gear (clutch side) will not line up at the same time on their covers marks at TDC. They are out a few degrees.
.


When you align the mark on the primary drive gear you have to be sure to be looking at the mark with your eyes parallel to center of the gear. If your eye level is above or below the gear and pointer the alignment will appear off a little. It is very easy to be off one tooth.



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