Well...I think I've done it now. I was installing my new YZF cam in my WR, and I think I have a serious problem, but I'm not positive.

Here's the deal...is there, or is there not a METAL timing chain guide? I had my cam out...everything was fine. I looked in the cam cover and there is a shield up there...so I assumed that was the guide mentioned in the manual. Anyway...I'm weaseling the new cam in and I heard that "jingle" noise...like something fell into the engine. But I looked down there with a light, and my timing chain had fallen down in, but I didn't see anything else. So, I assumed it was the chain falling in that made the noise.

So I get it about all back together (..no seat/tank), and I thought "I better just gently kick it to see if there's any binding, and sure enough, a half a kick and stuck.

So, here's my 2 possible problems. A.) I didn't align the cams up properly, and the compression release isn't releasing. Or B.) Is there a tin timing chain guide, that I somehow didn't see for the first 15 minutes of swapping cams, and trying to put the chain on???

The manual shows one, but I don't know if it's the plate in the top of the cover, or something that runs down by the chain, separately.

HELP!!!!! Is there a little metal guide that could have fallen down in my cases??? Or did I just mess up the timing?

Tex LaBo
'03 WR250F (Elbow crusher...now Timing screwer)
'01WR250F (Quickly becoming my favorite again)

You might want to check the c-clips that go between the cam bearing and cam cover. Most likey its one off those.

MXer...I may have just answered my own question. After I calmed down, I went back out...took off the cam cover, and pulled out the sparkplug. After I did that the motor spins freely, with little puffs of compression. So, I just have the cam in wrong, and it's not decompressing.

This years manual doesn't do that good of a job at explaining where the cams need to be. You can be a tooth off on either cam, and not really be able to tell.

I'll retry checking the cam timing to make sure they're right.

Labo
'03 WR250F (ILL)
'01 WR250F (Still perfect)

Okay...I take it back. You're right...the c-guide is missing from the exhaust cam. How in the hell am I supposed to get that back out of there, without splitting the cases or removing the jug???

Why did those morons design it that way!???! Couldn't they just mold the guides into the cam clamps, for pete's sake??!!!?!

I f-ing HATE my '03. It's been nothing but trouble from the day I bought it.

Any suggestions for retrieving the clip? I don't know just where that cavern goes to down the cam/chain tunnel.

BTW...I just double checked the manual...no pictures of the c-clips anywhere. Just one mention when removing the cam clamps, it says "Remove Bolts" "Remove Covers" "Clips". No pictures...no explainations..........jerks.

LaBo

>How in the hell am I supposed to get that back out of there, without splitting the cases or removing the jug???

Get one of those long magnetic probes they sell at electronic shops/auto shops. It's basically a long flexible magnetic stick. Remove cam cover and probe away.

I'm running to wal-mart right now....at midnight...to get one of those things. I'm so pissed. If I can't find it, I'm just going to throw the bike away, and take the loss.

I got screwed on the cam timing....didn't know you had to buy a whole new cam this year, until after I bought the bike.

This year, choked down takes on a whole new meaning. It takes twice as much work to make it run strong this time around.

The damn thing breaks my elbow on my 2nd ride, in a fluke fall against a tree going about 3 mph.

Now, replacing the cam, I drop a clip not shown in the manual down into the bottom end.

I mean seriously...sometimes there's just bad karma with some bikes, and I'm beginning to think that this is one of those bikes.

Thanks for the advice...

LaBo
'03 WR250Crap
'01 WR250Fun

You can pull the ign cover off and get the c-clip from there.

I dropped the clip in there when I did my YZ timing, even though I new about it. I used the magnet trick and it came right out (with a few cuss words and kids running for the closets ).

Good Luck

I thinke you need to drink so many beers that you can't spell right, and think about it in the tomorrow.

tex,
i think you need to take john_h's advice.

if nothing else, you drain the oil, pull the left cover and probably the flywheel and fish it out.

i hope all goes well.

one way to avoid part of this problem is to tie a piece of string to the chain and then to the footpeg. sure, the chain can drop, but you just pull the string and it comes right back up.

Sell your WR cam to those of us who want WR timing and get half your money back.
This spring when you are out roosting you will forget all of this!

What about getting a couple of friends, turning the thing upside down and shake the H :blush:LL out of it till the clip comes out?

TexLaBo - Sorry about your troubles, but there are so many posts on TT warning about dropping the 'C' clip into the engine when doing the e-cam swap (maybe you missed it) - even the 250F FAQ mentioned this on the autodecomp page (#3 under "Preparation"). As for the manual, to be fair to Yamaha, on page 4-23, the 'C' clip (or "clip", item #6) is shown in the diagram and it is also in the "Extent of removal" box - so this is written up in the manual!

Tex,
This happens alot and its not as bad as you think. With the telescopic magnet you will probably be able to get it out. If not, drain oil, remove flywheel cover, pop of flywheel and it will be right there. The cam chain tunnel is closed off and the clip will not get into the crank area. No splitting the cases or serious surgery required. 30 minute project. I found that putting the clip on the cam and lowering the cam cover onto it worked the best for me. Have fun!

Dude!
I feel your pain, I started my bike once in the parking lot... talk about pig! However, I took my time, did all the mods, changed the cam and...........Hooooold On! It truly rips! It's fast nimble and Bzzzz Vroom can't beat that button.
PS: If you throw it away, throw it MY way.
Good Luck, Hang in there, You'll be glad you did.
Bill

Well...here's the final outcome. I took the ignition cover off, and there it was. But, after I tried about 12 times, unsuccessfully, to get the cams set right, I finally took the bike to the dealership and told them to set the damn timing. I picked it up tonight....brought it home and fastened down the little butter-screws that hold the motor cap on. Reconnect the hoses. Double check every bolt and screw that I touched to make sure they're all torqued. Filled it up with oil. Started it up, and it purred nice and smooth. I let it idle for about 3 or 4 minutes, then re-checked the oil level, and it was perfect. So, I grab my helmet, and figure I'll do a little easy ridin' around my subdivision to kinda break it in and make sure everything runs right (...even put my quiet core back in). I head out of the garage, and get about a half block from the house...no more than 1/8 throttle...3rd gear...maybe 3k rpms, and suddenly "Kchuck"....lights go out...engine locks...and I coast to a stop. I gently kicked it a couple times to see if the motor locked up, or just screwed up. There's sporatic compression with lots of clunk noises and it doesn't even come close to starting, of course.

So...I stand by my mantra. I will take it back to the dealer and find out what they forgot to tighten in the cams, and have them repair it. Then I will sell it. I will never ride this bike again. Not to try it out...not to load it in the truck. It will sit until it's sold.

And THAT my friends, is the end of the story.

LaBo

But oh no...that was NOT the end of the story. After the dealership re-checked everything, and verified that it was fine. They said they all test rode it, and it was perfect. I told him "Good...if you know anyone looking for a new one, that doesn't want to pay $6k, I'll take $5k for it right now...it has less than 2 hours on it. He said he thought he knew a couple people, but don't give up on this bike. It's just awesome...don't let a small problem get in your way. The bike is perfect...keep riding it.

So, yesterday I went to the Texas Cross Country practice day, and I get 3 miles in and it siezes. So, there I am...in the middle of nowhere, with no idea even what direction it is to the pits if I wanted to push it. I wait about 5 minutes....try it...and it starts! So, I ease the clutch out, and get about 15 feet, and it siezes again!. So this time I park it for about a half hour while I wait for the TCCRA people to send back a 4-wheeler to drag it back to the pits. But, one guys stops, and when I tell him that he says "They don't do that on practice day. If you want a ride back or something, you can hop on." So, I said, well, it runs when it cools off...if you could just follow me till we hit an access road, I can take it from there." Well, after cooling off for 30 minutes or so, it starts right up, and I babied it along...not reving over 4k rpms...no more than 1/4 throttle...and I could feel it starting to get tight again when we'd hit a section with some hills or deep sand...but I babied it all the way back the rest of the loop and to the pits.

Monday, at 9am I will be at the dealers door, with my perfect bike, and my perfect story (..I had a helmet cam going, so I even have the evidence!). I should've listened to my little voice...but I let them talk me back into riding it, and that's what I get. So, I'm going to have them put the wr cam back in, and call whoever he knows, and have them pick it up. I don't even want to see this bike again.

I had intended to get a YZF, but this may have just ruined it for me for all the blue Fs. My '01 runs without a hitch. But, I needed the e-button, and new suspension and stuff...what a joke. I have a nephew with a CRF that has 4 rides on it that he might part with...I'll probably go that route at this point, I'm so furious.

Now THATS the end of the story. This bike could fall off a cliff for all I care, and I wouldn't even wonder where it went.

Tex

I almost did the same thing swapping back and fourth from WR to YZ timing to see which I liked best. I now put a very light coating of grease in the groove of the bearing and it holds the 1/2 moon clips in position while you fiddle the cam into position.
Rich K.