I really wanted to say THANKS! I had 5th gear go out on my Recon. Your videos were super helpful for the teardown and rebuild! I just can't thank you enough! The issue I had was that I broke 2 of the clutch spring bolts. One I broke when I was guessing, the other I broke with my torque wrench. Then, when it got time to torque other bolts, I was really afraid my new wrench wasn't right and I was way too tight and gonna break head studs. Once I got it fired up, I had a soft tick for about the first minute of idle, then it went away. So, I'll probably need re-watch your videos in a month after I blow this motor up!!
Sir this is the best series of videos I have ever seen you walked me through an engine teardown and reassembly and I have never done anything else like that, my 5th gear went out on my recon and I used all 3 videos on how to tear it down and put it back together, you saved me thousand from not having to buy another engine or pay someone to do it!!! I cant thank you enough!!!!
Very helpful video start to finish - we're in rural TN and I'm putting together my first 99 Recon 250 engine. The OEM manual and this video especially, a great help to get through it all.
Thank you was having a shifting problem with my recon and it was the stuff under the stator cover that you showed was messed up thank you for this video life saver🙏🏼
Thank you for the video! Saved me a huge headache. I chose the easy way and replaced shift shaft without taking motor out of frame. Your vid explained to me the orientation the shift drum pawl and reverse sensor line up and go in. 👍
If i may add a piece to it, I followed this video to a "T". this is my favorite person on youtube, however, the one thing i noticed you did not mention, the one way bearing inside the centrifugal clutch drum has a green dot on it (if not marked outside), make sure it goes in the right way, otherwise when the 4wheeler is put in gear, it'll stall. Love your videos man. You've helped me TONS!!!!!!
You are correct I did leave that out. I usually try to leave the clutch in the clutch bell when I remove them so that I don't have to mess with the one way bearing. Because if you ever drop one the little pieces will fall out and they're tough to get back together correctly and then like you say they have to be put back in correctly or the won't rotate in the correct direction. I'm glad I can help you out and keep watching, there's more videos to come.
@@FourwheelerDoctor I do have a question about the tuning. I bought a brand new Honda carb when I rebuilt the machine. (I used your rear end video, swing arm and steering stem bushing video too. Thank you again) I have a good amount of popping on deceleration but the bike runs good. Snappy throttle, lots of power. Do I need to rejet it?
It should have the correct jet in it if you got a Honda one but it probably wouldn't hurt to check the carb out to make sure there isn't something in the jets. I have have found small shards of metal in new carbs jets before. Normally a pop on deceleration mean it's running lean. Ride it around at night and see if your header pipe is glowing red. That's another sign it's running lean
I think I can do mine now but for sure I will be keeping you on my phone while I'm doing it so I can di it step by step thanks alot helped me to understand the side ways motor little bit better thanks for the video
How you doing Sr.! It is for me a very helpful this video, I never open a four wheel bike before, so I found all the details to rebuild it. Thank you so much Sr.
Hi there again! Apologies for interrupting your time Sr. I also hope you can guíame. Well, it turns out that the engine started smooth and nice. But when I activate reverse, the signal on the dash doesn't appear, and when going in gear, in third gear, that is where the reverse signal appears. What did I do wrong??? Thanks Sir, let me tell you that I have looked for information elsewhere and there is nothing. You're the only one. Thank God you are the only one. 👊
I have an 07 recon 250 that slams into first gear when you take off. all electric checks out and has new clutches. I also pulled the rear end apart but can find anything wrong. it shifts through the gears great just when first taking off it starts to rev them pops into gear. it even does it when using the Manuel shift bar. I have watched your tear down videos and not sure what to look for next. any ideas. thanks
I have a 2003 Honda recon 4 x 4 and the timing chain fell off so I was replacing the timing chain and I realized that that the The cam sprocket seems to turn about 3/4 of an inch each way is that right and And you have a great videos very well explain
Yes the cam will move back and forth as long as still have the head and push rods in place. That is the Lobe's of the cam hitting the cups trying to compress the valves. If the cam is not in the correct location for top dead center it can be rotated with some force to get into position.
Great video I managed to get mine back together and running but my neutral seems to be reverse. I don't suppose this is just a slight error and just needs slight adjustment? Any help would be very much appreciated
Hello Dr., I loved the details of your video. I've rebuilt mine twice watching your video step by step. The first time it shifted up to 5th gear then wouldn't come out of it. The second time, it won't shift out of neutral. Clearly I've messed up on the transmission. A couple gears fell off and I thought that I put them back on right but it seems I didn't. Any advice you can share or suggestions please?.
See if you can find you a manual online for a breakdown of the transmission. There's a bunch of washers, spacers and gears in there that have to be put back in the correct position. That's why when I tear one apart I usually pull the transmission all in one piece so that I don't have to mess with any other gears going back in the correct position but I do have manuals for if they do fall apart. Let me know if you can't find a breakdown because I can email you a couple pages if you needed me to.
I believe i forgot to put that washer on the shifter shaft back in and have been trying to adjust the clutch but dosent seem to want to shift right would that cause the issue it will shift just needs extra force sometimes
Hey man i have a quick question im rebuilding the same engine and that bottom gasket you said dont put silicone on. If i have already coated that gasket with copper spray do i need to toss it and get a new one? Also do i need some assembly lube for the cylinder when installing the piston into the cylinder. Reason i coated that gasket with copper spray was because one of the side head bolts broke off and i had to drill and tap it and the area near that bolt got a little scuffed up.
I just did a 250ex but I'm off somewhere I got it where I'm off one gear or something it's like reverse is where neutral should be be cus it shifts into reverse from first gear and starts in reverse and when I pull the lever and push down where reverse should be it goes into forward gear.
@@FourwheelerDoctor just verified it only bolts one way.. I am stumped. I blew Air though all port's on my 1997 250 recon. New cylinder, gaskets, oil pump,oil pump chain. Fresh Honda GN4 10w30 oil.. still not pumping oil to the head..
Your videos are super helpful, whenever I get a different 4 wheeler I always watch your videos to fix it. I just got a 2002 es recon that I’m kinda stumped on it I took all es stuff off and it still won’t shift manually I was wondering what you could think be wrong inside the motor I seen a other guys video about that round metal thing with the tab and tab on mine isn’t broke. Thank you so much!
The star shaped thing on mine is pointed in different directions and I was wondering it that has something to do with it my 4 wheeler is stuck in 2nd gear should I try spinning that thing to look like yours? How would I do that
@@FourwheelerDoctoryea I finally got the star shaped thing to rotate then I was able to put it together like you did I’m hoping it fixed now still have to put clutches back on
my trx250tm has eaten most of the cam chain teeth of the crankshaft is this common plenty crank kits for sale make me suspicious done small farm work only 1500 hours is that a lot chain badly stretched great videos any on crankshaft r/r ? please and thankyou in advance
Hi Doc , Well I got all the parts to put the pull start on my Sportrax but I can't get the bolt out of the end of the crank to budge , even with my air impact . I was thinking about renting a bigger impact with more power but i'm having thoughts about that bolt breaking off in there . I know I've got my impact set right , lefty loosie , I'm stumped , Why is it so Dang tight ? Got any thoughts , Ideas or tricks up your sleve ?
@@FourwheelerDoctor Thanks Doc , I'll go get a bigger Impact . I appreciate you sharing your Knowledge , Thank you very much . I'll let you know how things turn out .
I’m in the middle of rebuilding my 2001 Honda recon 250 trx(foot shift) and I I’ve got it all apart and the gearshift drum is different I can’t stick a screwdriver in the drum to get it in neutral it’s different from the one you’re working on but I can turn the transmission and get the gear drum to go back one click and that’s it it won’t do any more. IN NEED OF HELP PLEASE!!!!
Hey Doc, got a question hopefully you can help with, the Ole inter-web isn't much help..... the one I'm working on is a foot shift (wasn't running when I bought it) the shift mechanism works great with the clutch cover off or when I put it on and run the bolts finger tight. If I torque the bolts down, the shifter will still engage but its hard as hell to shift and the shifter won't return to normal position. It's like there is something binding. But I can for the life of me figure it out I've changed shift linkages, shift arm, checked and rechecked the washers. Any ideas?
Check and make sure the mechanism that slides over the shift shaft is sliding all the way down to the washer and the case. I've had them ride out just a little bit before and the case not bolt up right
I have a 2021 250x. And adjust the valves says the last needs to be between .005 to .001. Would you adjust all the way to .001 or between .001 amd .005
So i just rebuilt my 99 recon 250. Rebuilt the top end, cleaned and seated the valves, checked both clutches, etc. Bike runs like an absolute champ. It only has one issue. I replaced the one way bearing in the centrifugal clutch because it was going bad. Now, when I go to put it in first gear, it's really "grabby" and stalls on me. the only way I can keep it from stalling is by revving it up before I shift into first and I know its just a matter of time before I break something else. Also it doesn't want to stop when in gear it will try to crawl through the brake until it stalls itself out. What did I do wrong and how can I fix it? hopefully you see this soon...
Four wheeler Doctor it’s got a notch on it and I tried putting it in on the side the notch is and I couldn’t get it in. I’m sure you’ve done them before? Which way does the notch have to be
Four wheeler Doctor okay. Nothing was stamped on it. I checked. Nothing stamped on the old one either. I’ll tear it back apart and check it. Thanks for all your help.
I have a 1999 honda recon and cant find a crank shaft for, but i can find one for a 2002. Will a 2002 crankshaft work in a 1999 or is there a difference cant find anything to tell me if it will or it wont. thank you! your videos have helped alot
Man that's some intense stuff your doing there I just bought a Recon that is stuck in reverse and in the emergency shifter will not budge a bit either way. Any advice for me?
I ran my 2008 Honda recon before thanksgiving with no issues. I come home for Christmas and I cannot get it to start, I cleaned the carburetor, I have a wet plug and I have spark, while trying to start the engine I had one hell of a back fire! Any ideas?
I have my motor all put back together and everything was spinning but when I put the starter in it wouldn’t turn over the starter is still good I took the starter back off and the gears from the starter to the flywheel where locked up but I could still spin the engine using the flywheel bolt I took the rear cover off and the gears freed up but I put the starter back in again and the gears locked up again any ideas?
Is the one way bearing on the flywheel working? It should spin One direction and not the other. I'm not real sure what could be binding up on them since nothing has a washer except that one Jack shaft piece. Do you have that washer in the correct location?
I usually use oem weights but actually just got a caltrac clutch in the mail today for a 300. I haven't ever used one yet.Stay tuned for a install video on it in the next few days.
If you have looked around online there are tons of opinions on which oil to use. The engines use a wet clutch that runs in the oil. I use a motorcycle rated conventional oil. The synthetic oil is good stuff and the only advice I could give you is just make sure yours is rated for wet clutch use.
Hey I just put a new crankshaft in my 03 250ex and I got it all back together and it’ll shift into reverse but not back into neutral and won’t shift any more but that. Got any ideas?
Bought a 99 Honda recon 250 that sat up for a good while. Replaced carb and found that the bike Is burning a good bit of oil. What would be your next steps to diagnosis and fix this problem? Thank you for taking the time to produce these videos. They are awesome!
Sometimes if one sets up it'll get moisture in the cylinder and will rust it. I'm not saying that's the case but I've seen it happen before. You either need to replace your rings on your piston or have the cylinder board out. And as long as your bottom end tight and clean your motor should be good to go after that.
Hello again Doc , Just wanted to thank you again for sharing your knowledge . My Sportrax runs like a New sewing machine sliding down a buttered marshmallow . Here's a question I can't seem to find an answer for : Can you put a pull starter off a Recon onto a Sportrax ? Seems like it could come in handy in certain situations . Thanks again Doc .
It seems like it would work. But you also have to get the part that goes on the end of the crankshaft. So that the pull start will have something to grab onto
@@FourwheelerDoctor Thanks Doc , That's kinda what I was thinking , looks like the bolt holes would line right up . The pull starters are easily available on E-Bay . Now all I have to find is that 4 eared part that goes on the end of the crankshaft . The search is on . If I can make it work i'll let you know . Thanks Again Doc .
Rebuilt my entire motor using your video. But I am on my very last piece (clutch cover) and I cannot get this cover to go on for the life of me. It seems as if something isn’t lined up correctly keeping it from setting down but I’ve triple checked everything and nothing is out if order. Any advice would be appreciated! Great video by the way!
Most is the time it will catch on the bearing and the end of the crankshaft. Make sure it is going down on the case square. If one side is lower than the other it will not slide down. Also make sure your alignment dowels are in the correct place and not stacked on top of on another
Help my dad and I followed this video to rebuild this exact motor. Halfway through the rebuild installing the piston I did not think to put a rag in the crankcase and as a result I dropped a wrist pin clip that came with the new piston from Namura. Stupid me! My homemade magnet on a string sticks to everything inside the engine so it is a bust, and I don't want to take it apart again and start over. Before we throw some money at a telescoping magnet, am I out of luck? Cheers
If you have the motor out of the bike you can always try and turn it upside down and try to shake it out. If that doesn't work then your only other option other than splitting it is the telescoping magnet. The good thing is that the magnet will not stick to the crankcase so if you can get it down past the crankshaft you may be able to fish it out.
I removed the transmission drive shaft gears and washers and it all fell to floor and now idont know witch way the gears and washers goes back on the drive shaft
Hello again, excuse me when you tighten the four screws on the head, how many kilos of pressure are there and also the two lateral ones, the 10 mm ones, I just need to know that to finish my friend?
@@FourwheelerDoctor I broke one of the screws, the worst thing that could have happened happened, they were old screws, it broke at the very root now to go to the lathe haha no way
Hi...love your videos...is it possible to do a cam chain with the engine in situ and without removing the cylinder head etc...I can see I'd have to use magnets after removing the pushrods...also, I was gonna change the oil pump chain while I'm at it but find it a bit surprising there's no tensioner on it thanks
Yes there is but like you said you would have to use magnets to hold up on the cam followers. There are a number of different brand ATVs that don't have tensioners on the oil pump chain. I have a seem a few of them come off as well which can turn out really bad.
Hi Doc, I had a bad timing chain like noise on my trx 250 ex 2006, so I replaced both chains after that I still have the same high pitched noise but I noticed that the noise goes away when I pull in the clutch. Do you have any advice as to what it could be. Thanks Gavin.
Checked clutches today. They are all fine but now my manual clutch is not working. Not enough travel when I pull the Lever. I must have assembled it wrong but I can't see what I done wrong. The pressure disc does not reach the bearing. Please help.
@@gavinmarais3651 sometimes the change clutches will only got together one way. Try and rotate the outer part of the clutch. Also make sure all of the tabs are in line in the clutch disks
@@FourwheelerDoctor hi Doc, the bike starting fine but then it gave A very load ping when I started it later and does nothing but give a loud ping when trying to start it. Please help Doc.
Hi. I followed your video pretty well. I have one issue. Nuetral light comes on and turn it over but it moves as if it were in first gear. It will go into reverse and any gear but once in neutral, it moves as if it were in first gear when I rev it. Thank you in advance
I’ve tried to put it back together twice now and I get it in neutral and it spins both way hen I go to put it on the 4 wheeler it locks up and I can’t shift up or down any idea??
If you remove the front cover on the bike will it start back shifting? Sounds like you don't have something quite right with the parts that bolt to the shift drum.
Four wheeler Doctor I can feel it clicking it will go up into first but won’t go back down to neutral Even with twisting the transmission shaft coming out the back of the engine
No I don't. I just do this in addition to my 40 hour a week job. As you can imagine I stay swamped with local work and I'm not trying to take on any more.
how in the hell did you get the cam chain on? im trying to change just my cam chain. havnt pulled cam or anything. my new chain doesnt go right of. i could probabyl spin it on but havnt put much time into it yet.
You have to pull the cam out at least a little bit to allow the cam gear to move closer to the crankshaft. You'll also want to pull the push rods out and it's not a bad idea to stick to magnets down in the push rod holes to keep the cam follower cups from falling into the crankcase
Hi friend from jalisco mexico i have a sportrax 250 ex 2003 and i change the valves but i dont know what is the calibration for the exaust and the intake valve can you say me the corret number please im sorry for my english i hope can you helpme please the clearance
I can do it in 4 to 5 total. The thing that seems to slow me down the most is cleaning the case and engine covers out and removing the old gaskets to replace with new ones. If you aren't very mechanically inclined or if you don't have power/air tools I would probably figure on 7 to 8 hours.
@@FourwheelerDoctor Ok thank you thats good to know. I want to rebuild my 97 recon because there can sometimes be a grinding and clunking(?) sound shifting up to 3rd and 4th. What would you say is the most difficult part for a first timer? And also if you have any ideas why it might grind that would be helpful as well.
@@AndouilleSlim I'm not sure what that may be. Could be a bent shift fork or could even be worn clutches. I think the hardest part for a beginner would either be getting the transmission back together or most seem to struggle with the timing. A manual would help both tremendously.
My friend wants me to replace the valve seals on his Honda 250EX. I have been watching some of your videos and they are very good. The only problem with this 250EX is the valve seals. My question is, is it possible to replace the valve seals without taking the head off? I have replaced valve seals on several cars. I just don't want to take the head off if I don't have to. Thanks
If you have ever done a car while leaving the head on then you can do it on the ATV. You will have to come up with some way to keep the valve up as you take the valve spring off just like on a car. In all honesty it is just as simple to pull the head. You will not have to deal with any timing since the cams are in the bottom ends on the 250.
@@FourwheelerDoctor I usually take the spark plug out and hook my air compressor up to it to keep the valves from dropping. It's probably like you said, to be easier to just pull the head.
@@FourwheelerDoctorIt looks like I am gonna have to replace the piston and rings to get it to quit smoking. I think you said you put a .025 oversized piston and cleaned up the cylinder walls. Where you able to do that with just a cylinder hone or did you have to have that bored out? Also this 250 EX I'am working on do you think it being a 2001 I should replace the cam chain also? Thanks very much for your knowledge and help.
I get the inside clean but usually don't mess with the outside. Most of the ones I work on are mud riders so they are right back dirty again after the first ride. But If you do want to clean one, a pressure washer and some etching rim cleaner will do wonders on the aluminum
DOC, ILL PAY YOU $500.00 OVER WHAT YOU NORMALLY CHARGE FOR THIS SERVICE, IF YOU WILL PLEASE DO THIS FOR MY RECON ENGINE. WILL YOU DO IT FOR ME? I AM IN GEORGIA AND CAN DELIVER THE MOTOR TO YOUR HOUSE OR I WILL SHIP IT TO YOU. TAKE AS LONG AS YOU NEED TO GET IT DONE. THE ATV HAS SENTIMENTAL VALUE TO ME AND IM WILLING TO PAY A PREMIUM PRICE TO GET THE MOTOR TORN DOWN AND SEE IF ANYTHING NEEDS TO BE REPLACED. LET ME KNOW SIR. THANK YOU
I just picked up a 2001 250 recon she's stuck I neutral?? I'm about to pop the front off I'm hoping to fix it myself. But the header cylinder piston top block and rockers are trashed any advice
No telling what may have it stuck in gear. But if you pull the front cover off you'll probably find the problem. As far as the cylinder and head goes you can usually pick up used parts or new parts up on eBay at a very reasonable price so probably wouldn't be much to rebuild it.
Sir, this is probably the best engine rebuild video I have ever seen. Thank you.
Thanks!!
I really wanted to say THANKS! I had 5th gear go out on my Recon. Your videos were super helpful for the teardown and rebuild! I just can't thank you enough!
The issue I had was that I broke 2 of the clutch spring bolts. One I broke when I was guessing, the other I broke with my torque wrench. Then, when it got time to torque other bolts, I was really afraid my new wrench wasn't right and I was way too tight and gonna break head studs. Once I got it fired up, I had a soft tick for about the first minute of idle, then it went away. So, I'll probably need re-watch your videos in a month after I blow this motor up!!
"Holdin' my mouth right" has become common practice because of you... it really makes a difference!!
Lol let's start a revolution! It definitely takes some practice. Thanks for watching
Sir this is the best series of videos I have ever seen you walked me through an engine teardown and reassembly and I have never done anything else like that, my 5th gear went out on my recon and I used all 3 videos on how to tear it down and put it back together, you saved me thousand from not having to buy another engine or pay someone to do it!!! I cant thank you enough!!!!
Great glad I could help
The Timing, Torque specs, sealants or no sealants… I like how you are very detailed! Thank you again! 👍🏻😊
Thanks man, I try to explain it were someone with little to no mechanical ability can do it without questions.
Thank you for the video!!! Very very helpful!!!!!!! Thank you!!!!!!! Lord bless you and your family.❤❤❤
Thanks for making this video. The step by step guidance gave me the confidence to tackle a full rebuild.
Very helpful video start to finish - we're in rural TN and I'm putting together my first 99 Recon 250 engine. The OEM manual and this video especially, a great help to get through it all.
Where did u find the kit to rebuild your 99 250
Thanks for the video. All I needed was the information on how to put the automatic shift gears back together. You solved two of my problems.
Glad I could help. Thanks for watching
Thank you sir! This is the only video you'll need if you'll be doing a rebuild on a recon/sportrax.
Thanks and thanks for watching
I’m having a hard time holding my mouth right. Can you do a break down video on that?
Nah i’m kidding another great video!
Thank you was having a shifting problem with my recon and it was the stuff under the stator cover that you showed was messed up thank you for this video life saver🙏🏼
Glad I could help and thanks for watching
Thank you for the video! Saved me a huge headache. I chose the easy way and replaced shift shaft without taking motor out of frame. Your vid explained to me the orientation the shift drum pawl and reverse sensor line up and go in. 👍
Glad I could help!
Want to thank you for this video, it has taught me a lot and saved me alot$$$. Best video on this subject that you tube has.
Thanks man! Stay tuned, I'm about to upload a couple more videos rebuilding the swing arm and differential on a 250 recon.
If i may add a piece to it, I followed this video to a "T". this is my favorite person on youtube, however, the one thing i noticed you did not mention, the one way bearing inside the centrifugal clutch drum has a green dot on it (if not marked outside), make sure it goes in the right way, otherwise when the 4wheeler is put in gear, it'll stall. Love your videos man. You've helped me TONS!!!!!!
You are correct I did leave that out. I usually try to leave the clutch in the clutch bell when I remove them so that I don't have to mess with the one way bearing. Because if you ever drop one the little pieces will fall out and they're tough to get back together correctly and then like you say they have to be put back in correctly or the won't rotate in the correct direction. I'm glad I can help you out and keep watching, there's more videos to come.
@@FourwheelerDoctor I do have a question about the tuning. I bought a brand new Honda carb when I rebuilt the machine. (I used your rear end video, swing arm and steering stem bushing video too. Thank you again)
I have a good amount of popping on deceleration but the bike runs good. Snappy throttle, lots of power. Do I need to rejet it?
It should have the correct jet in it if you got a Honda one but it probably wouldn't hurt to check the carb out to make sure there isn't something in the jets. I have have found small shards of metal in new carbs jets before. Normally a pop on deceleration mean it's running lean. Ride it around at night and see if your header pipe is glowing red. That's another sign it's running lean
@@FourwheelerDoctor okay. I’ll check it out and see. Thank you!
I think I can do mine now but for sure I will be keeping you on my phone while I'm doing it so I can di it step by step thanks alot helped me to understand the side ways motor little bit better thanks for the video
it runs yay ! Thankyou new crank from hotrods
Change your timming chain regular folks thx again good usable vidieo
How you doing Sr.! It is for me a very helpful this video, I never open a four wheel bike before, so I found all the details to rebuild it. Thank you so much Sr.
Glad I could help thanks for watching
Hi there again! Apologies for interrupting your time Sr.
I also hope you can guíame.
Well, it turns out that the engine started smooth and nice. But when I activate reverse, the signal on the dash doesn't appear, and when going in gear, in third gear, that is where the reverse signal appears.
What did I do wrong??? Thanks Sir, let me tell you that I have looked for information elsewhere and there is nothing. You're the only one. Thank God you are the only one. 👊
I got that fix already!!! Thank you Sr!!!
@@angelalvarez9349 was it your shift sensor?
@@FourwheelerDoctor yes, it wasn't in the right position. Yeah, You just put money in my wallet... Lol🤑... 👊😊
glad you done this one
Thanks and thanks for watching?
Thank you great video helped me out alot
I have an 07 recon 250 that slams into first gear when you take off. all electric checks out and has new clutches. I also pulled the rear end apart but can find anything wrong. it shifts through the gears great just when first taking off it starts to rev them pops into gear. it even does it when using the Manuel shift bar. I have watched your tear down videos and not sure what to look for next. any ideas. thanks
Thanks so much for the help man
Glad I could help.
I have a 2003 Honda recon 4 x 4 and the timing chain fell off so I was replacing the timing chain and I realized that that the The cam sprocket seems to turn about 3/4 of an inch each way is that right and And you have a great videos very well explain
Yes the cam will move back and forth as long as still have the head and push rods in place. That is the Lobe's of the cam hitting the cups trying to compress the valves. If the cam is not in the correct location for top dead center it can be rotated with some force to get into position.
@@FourwheelerDoctor Thanks for the help
Great video I managed to get mine back together and running but my neutral seems to be reverse. I don't suppose this is just a slight error and just needs slight adjustment? Any help would be very much appreciated
Thanks well done video
Thanks and Thanks for watching.
Hello Dr., I loved the details of your video. I've rebuilt mine twice watching your video step by step. The first time it shifted up to 5th gear then wouldn't come out of it. The second time, it won't shift out of neutral. Clearly I've messed up on the transmission. A couple gears fell off and I thought that I put them back on right but it seems I didn't. Any advice you can share or suggestions please?.
See if you can find you a manual online for a breakdown of the transmission. There's a bunch of washers, spacers and gears in there that have to be put back in the correct position. That's why when I tear one apart I usually pull the transmission all in one piece so that I don't have to mess with any other gears going back in the correct position but I do have manuals for if they do fall apart. Let me know if you can't find a breakdown because I can email you a couple pages if you needed me to.
How would you suggest I get the two center cases put together
Where can I find the complete engine rebuilding kit for a 1997 honda recon 250..2wd
Merry christmas
I believe i forgot to put that washer on the shifter shaft back in and have been trying to adjust the clutch but dosent seem to want to shift right would that cause the issue it will shift just needs extra force sometimes
Thank you man good job
Thank you! I really appreciate your videos. 👍🏻😊⚙️🛞
Thanks and thanks for watching
Hey man i have a quick question im rebuilding the same engine and that bottom gasket you said dont put silicone on. If i have already coated that gasket with copper spray do i need to toss it and get a new one? Also do i need some assembly lube for the cylinder when installing the piston into the cylinder. Reason i coated that gasket with copper spray was because one of the side head bolts broke off and i had to drill and tap it and the area near that bolt got a little scuffed up.
Will you be able to rebuild my engine I should have everything back from machine shop next week
Check your email
Thank you
Thanks and thanks for watching
I just did a 250ex but I'm off somewhere I got it where I'm off one gear or something it's like reverse is where neutral should be be cus it shifts into reverse from first gear and starts in reverse and when I pull the lever and push down where reverse should be it goes into forward gear.
Thanks 👍🏼
Merry christmas four weler
When I get the 2 cases together the shift drum spins a little but will not shift gears what’s wrong?
Hey boss what size do I gap the piston rings?
Is it possible to bolt in the oil pump backwards?
I don't think so
@@FourwheelerDoctor just verified it only bolts one way.. I am stumped. I blew Air though all port's on my 1997 250 recon. New cylinder, gaskets, oil pump,oil pump chain. Fresh Honda GN4 10w30 oil.. still not pumping oil to the head..
Your videos are super helpful, whenever I get a different 4 wheeler I always watch your videos to fix it. I just got a 2002 es recon that I’m kinda stumped on it I took all es stuff off and it still won’t shift manually I was wondering what you could think be wrong inside the motor I seen a other guys video about that round metal thing with the tab and tab on mine isn’t broke. Thank you so much!
The star shaped thing on mine is pointed in different directions and I was wondering it that has something to do with it my 4 wheeler is stuck in 2nd gear should I try spinning that thing to look like yours? How would I do that
@@dylanrobinson9261 will the star shaped piece rotate?
@@FourwheelerDoctoryea I finally got the star shaped thing to rotate then I was able to put it together like you did I’m hoping it fixed now still have to put clutches back on
@@FourwheelerDoctorthank you for the response!
What year is that motor my 2017 don’t look like that
my trx250tm has eaten most of the cam chain teeth of the crankshaft is this common plenty crank kits for sale make me suspicious
done small farm work only 1500 hours is that a lot chain badly stretched
great videos
any on crankshaft r/r ? please and thankyou in advance
How did you put the clutch on without the piston and stuff moving and slapping everything ?
You can hold the clutch with your hand enough to tighten it with an impact.
Hi Doc , Well I got all the parts to put the pull start on my Sportrax but I can't get the bolt out of the end of the crank to budge , even with my air impact . I was thinking about renting a bigger impact with more power but i'm having thoughts about that bolt breaking off in there . I know I've got my impact set right , lefty loosie , I'm stumped , Why is it so Dang tight ? Got any thoughts , Ideas or tricks up your sleve ?
Sometimes they are real tight. Just try a bigger impact. I've never had a bolt brake off in one
@@FourwheelerDoctor Thanks Doc , I'll go get a bigger Impact . I appreciate you sharing your Knowledge , Thank you very much . I'll let you know how things turn out .
I’m in the middle of rebuilding my
2001 Honda recon 250 trx(foot shift) and I I’ve got it all apart and the gearshift drum is different I can’t stick a screwdriver in the drum to get it in neutral it’s different from the one you’re working on but I can turn the transmission and get the gear drum to go back one click and that’s it it won’t do any more. IN NEED OF HELP PLEASE!!!!
Part of the video I’m talking about is 12:12
Hey Doc, got a question hopefully you can help with, the Ole inter-web isn't much help..... the one I'm working on is a foot shift (wasn't running when I bought it) the shift mechanism works great with the clutch cover off or when I put it on and run the bolts finger tight. If I torque the bolts down, the shifter will still engage but its hard as hell to shift and the shifter won't return to normal position. It's like there is something binding. But I can for the life of me figure it out I've changed shift linkages, shift arm, checked and rechecked the washers. Any ideas?
Check and make sure the mechanism that slides over the shift shaft is sliding all the way down to the washer and the case. I've had them ride out just a little bit before and the case not bolt up right
Where do you order these parts what link
I have a 2021 250x. And adjust the valves says the last needs to be between .005 to .001. Would you adjust all the way to .001 or between .001 amd .005
On Hondas I normally like to adjust between the tightest and the middle because the always seem to loosen up over time.
So i just rebuilt my 99 recon 250. Rebuilt the top end, cleaned and seated the valves, checked both clutches, etc. Bike runs like an absolute champ. It only has one issue. I replaced the one way bearing in the centrifugal clutch because it was going bad. Now, when I go to put it in first gear, it's really "grabby" and stalls on me. the only way I can keep it from stalling is by revving it up before I shift into first and I know its just a matter of time before I break something else. Also it doesn't want to stop when in gear it will try to crawl through the brake until it stalls itself out. What did I do wrong and how can I fix it? hopefully you see this soon...
Are you sure you put the bearing in the correct way? Sounds like you're one way bearings backwards
Four wheeler Doctor it’s got a notch on it and I tried putting it in on the side the notch is and I couldn’t get it in. I’m sure you’ve done them before? Which way does the notch have to be
It should of had outside stamped on it. The surefire way to check is hold the clutch bell and try and rotate the clutches. They should turn clockwise.
Four wheeler Doctor okay. Nothing was stamped on it. I checked. Nothing stamped on the old one either. I’ll tear it back apart and check it. Thanks for all your help.
my shifter wont stay in motor i have the new parts
I have a 1999 honda recon and cant find a crank shaft for, but i can find one for a 2002. Will a 2002 crankshaft work in a 1999 or is there a difference cant find anything to tell me if it will or it wont. thank you! your videos have helped alot
Did u ever find a kit
Man that's some intense stuff your doing there I just bought a Recon that is stuck in reverse and in the emergency shifter will not budge a bit either way. Any advice for me?
What if shift shaft won’t go in all the way?
Can the oil pump be changed without pulling the clutch?
It can be done but it may be tough keeping the chain on the crankshaft
I ran my 2008 Honda recon before thanksgiving with no issues. I come home for Christmas and I cannot get it to start, I cleaned the carburetor, I have a wet plug and I have spark, while trying to start the engine I had one hell of a back fire! Any ideas?
That's odd. Check your valve clearance
I have my motor all put back together and everything was spinning but when I put the starter in it wouldn’t turn over the starter is still good I took the starter back off and the gears from the starter to the flywheel where locked up but I could still spin the engine using the flywheel bolt I took the rear cover off and the gears freed up but I put the starter back in again and the gears locked up again any ideas?
Is the one way bearing on the flywheel working? It should spin One direction and not the other. I'm not real sure what could be binding up on them since nothing has a washer except that one Jack shaft piece. Do you have that washer in the correct location?
What kind of gasket paste did you use?
Permatex gray rtv
how much did you twork the bolts on the top
The head nuts go to 22 ft-lb
Merry crhismas four weller
Is the caltric centrifugal any good for these ?
I usually use oem weights but actually just got a caltrac clutch in the mail today for a 300. I haven't ever used one yet.Stay tuned for a install video on it in the next few days.
Correction the one I got in the mail is for a recon.
Four wheeler Doctor gotcha
Where u Located I need my 250 Honda recon rebuilt
I have four 2005 recons, they all run good. I bought one new and the rest slightly used. I recently started using full synthetic oil, is that ok?
If you have looked around online there are tons of opinions on which oil to use. The engines use a wet clutch that runs in the oil. I use a motorcycle rated conventional oil. The synthetic oil is good stuff and the only advice I could give you is just make sure yours is rated for wet clutch use.
Thanks!
Hey I just put a new crankshaft in my 03 250ex and I got it all back together and it’ll shift into reverse but not back into neutral and won’t shift any more but that. Got any ideas?
Sounds like something is wrong with your shift fork. I have never had one do this before. Was it shifting correctly before you took it apart?
Bought a 99 Honda recon 250 that sat up for a good while. Replaced carb and found that the bike Is burning a good bit of oil. What would be your next steps to diagnosis and fix this problem?
Thank you for taking the time to produce these videos. They are awesome!
Sometimes if one sets up it'll get moisture in the cylinder and will rust it. I'm not saying that's the case but I've seen it happen before. You either need to replace your rings on your piston or have the cylinder board out. And as long as your bottom end tight and clean your motor should be good to go after that.
hey man! i have a quention
how many nm does the clutch spring bolts take?
Around 12nm
is there no need for assembly lube on these rebuilds?
Sometimes I do put some assembly lube on the Piston pin if it's nearby otherwise I just use oil on everything.
Hello again Doc , Just wanted to thank you again for sharing your knowledge . My Sportrax runs like a New sewing machine sliding down a buttered marshmallow . Here's a question I can't seem to find an answer for : Can you put a pull starter off a Recon onto a Sportrax ? Seems like it could come in handy in certain situations . Thanks again Doc .
It seems like it would work. But you also have to get the part that goes on the end of the crankshaft. So that the pull start will have something to grab onto
@@FourwheelerDoctor Thanks Doc , That's kinda what I was thinking , looks like the bolt holes would line right up . The pull starters are easily available on E-Bay . Now all I have to find is that 4 eared part that goes on the end of the crankshaft . The search is on . If I can make it work i'll let you know . Thanks Again Doc .
Can you still find timing chains for these engines?
Yeah you should be able to since the recon’s are still made today and use basically the same engine.
Rebuilt my entire motor using your video. But I am on my very last piece (clutch cover) and I cannot get this cover to go on for the life of me. It seems as if something isn’t lined up correctly keeping it from setting down but I’ve triple checked everything and nothing is out if order. Any advice would be appreciated! Great video by the way!
Most is the time it will catch on the bearing and the end of the crankshaft. Make sure it is going down on the case square. If one side is lower than the other it will not slide down. Also make sure your alignment dowels are in the correct place and not stacked on top of on another
Hi Doc. My friend needs a one way clutch bearing. Are the Caltric one way bearings a good deal or should we put OEM Honda in it? Thanks
I have used them before with no issue.
@@FourwheelerDoctor thanks for sharing.
Help my dad and I followed this video to rebuild this exact motor. Halfway through the rebuild installing the piston I did not think to put a rag in the crankcase and as a result I dropped a wrist pin clip that came with the new piston from Namura. Stupid me! My homemade magnet on a string sticks to everything inside the engine so it is a bust, and I don't want to take it apart again and start over. Before we throw some money at a telescoping magnet, am I out of luck? Cheers
If you have the motor out of the bike you can always try and turn it upside down and try to shake it out. If that doesn't work then your only other option other than splitting it is the telescoping magnet. The good thing is that the magnet will not stick to the crankcase so if you can get it down past the crankshaft you may be able to fish it out.
@@FourwheelerDoctor I did get it out with a flexible magnet stick as of right now it runs great
@@jordananderson8299 good deal. My luck normally isn't that good. Lol I'm glad my video helped you out.
Where did you find your parts for this motor?
Hello sir was wondering where 🤔 u get ur cam chain an oil pump chain an gaskets
Or is there a kit that u get can u post some links in comments please
I usually just use the one stuff for these items. Check out motosport.com or partzilla.com
I removed the transmission drive shaft gears and washers and it all fell to floor and now idont know witch way the gears and washers goes back on the drive shaft
this should help
Hello again, excuse me when you tighten the four screws on the head, how many kilos of pressure are there and also the two lateral ones, the 10 mm ones, I just need to know that to finish my friend?
The acorn nuts a 22 ft-lb or 3 kg-m and the 10 mm bolts are 9 ft-lb or 1.25 kg-m.
@@FourwheelerDoctor I broke one of the screws, the worst thing that could have happened happened, they were old screws, it broke at the very root now to go to the lathe haha no way
Hi Doc, I would like to send you a video but it does not want to send to you tube, is there any other address I can send it to. Thanks.
fourwheelerdoctor@gmail.com
Hi...love your videos...is it possible to do a cam chain with the engine in situ and without removing the cylinder head etc...I can see I'd have to use magnets after removing the pushrods...also, I was gonna change the oil pump chain while I'm at it but find it a bit surprising there's no tensioner on it thanks
Yes there is but like you said you would have to use magnets to hold up on the cam followers. There are a number of different brand ATVs that don't have tensioners on the oil pump chain. I have a seem a few of them come off as well which can turn out really bad.
@@FourwheelerDoctor thanks for your excellent quick reply !!!!
Do they have a gear reduced for it
Not that I know of
Is there a Pacific ring gap??
The gap is different for each ring.
Top 0.2-0.35 mm
Second 0.4-0.55mm
Oil (side rails) 0.2-0.7mm
Hi Doc, I had a bad timing chain like noise on my trx 250 ex 2006, so I replaced both chains after that I still have the same high pitched noise but I noticed that the noise goes away when I pull in the clutch.
Do you have any advice as to what it could be. Thanks Gavin.
Not sure what that may be unless it's you clutch plates shaking in the clutch basket due to side wear.
@@FourwheelerDoctor I will check that tomorrow, thanks
Checked clutches today. They are all fine but now my manual clutch is not working. Not enough travel when I pull the Lever. I must have assembled it wrong but I can't see what I done wrong. The pressure disc does not reach the bearing. Please help.
@@gavinmarais3651 sometimes the change clutches will only got together one way. Try and rotate the outer part of the clutch. Also make sure all of the tabs are in line in the clutch disks
@@FourwheelerDoctor hi Doc, the bike starting fine but then it gave A very load ping when I started it later and does nothing but give a loud ping when trying to start it. Please help Doc.
Hi. I followed your video pretty well. I have one issue.
Nuetral light comes on and turn it over but it moves as if it were in first gear. It will go into reverse and any gear but once in neutral, it moves as if it were in first gear when I rev it. Thank you in advance
Try adjusting your clutch
@@FourwheelerDoctor thank you. I will give it a try and get back to you with results
Hay man can you pm me I was wondering how much you charge on a top end rebuild
I’ve tried to put it back together twice now and I get it in neutral and it spins both way hen I go to put it on the 4 wheeler it locks up and I can’t shift up or down any idea??
If you remove the front cover on the bike will it start back shifting? Sounds like you don't have something quite right with the parts that bolt to the shift drum.
Make sure the welded part is in the center of the fork. I talked about it at 43:25. It can make the shift shaft bind after you put the front cover on.
Four wheeler Doctor I can feel it clicking it will go up into first but won’t go back down to neutral Even with twisting the transmission shaft coming out the back of the engine
Where did u order the new clutch shoes ?
I get all of my oem parts from Mr cycles out of Ashville nc.
Do you offer rebuilding services? I have one I’d like to send out and have gone through too to bottom and freshened up. Thank you
No I don't. I just do this in addition to my 40 hour a week job. As you can imagine I stay swamped with local work and I'm not trying to take on any more.
Four wheeler Doctor No worries thank you.
how in the hell did you get the cam chain on? im trying to change just my cam chain. havnt pulled cam or anything. my new chain doesnt go right of. i could probabyl spin it on but havnt put much time into it yet.
You have to pull the cam out at least a little bit to allow the cam gear to move closer to the crankshaft. You'll also want to pull the push rods out and it's not a bad idea to stick to magnets down in the push rod holes to keep the cam follower cups from falling into the crankcase
@@FourwheelerDoctor cool thank you
Is it possible to get cam back in without pulling top of motor?
You have to pull the top off and get the push rods out. Then take two magnets to hold up the two cam followers
Can you rebuild mine same one as that will pay
As you can imagine I have people waiting in line and it's a long line.
Hi friend from jalisco mexico i have a sportrax 250 ex 2003 and i change the valves but i dont know what is the calibration for the exaust and the intake valve can you say me the corret number please im sorry for my english i hope can you helpme please the clearance
Greetings from South Carolina. You valve clearance should be .13 mm or .005 in. For both valves
@@FourwheelerDoctor thanks very much buddy
@@FourwheelerDoctor At the time of the video, where he puts the fire packaging at 1:11:18, does the packaging contain high-temperature silicone?
@@JoseRomero-xx1xl I use a spray on the gasket called copper seal. It is not a silicone.
@@FourwheelerDoctor o ok Thank you very much friend thanks to the video and the answers I can already rebuild my sportrax myself thank you very much
How many work hours would you say it takes from getting the engine out, rebuilding it, and putting it back on the bike?
I can do it in 4 to 5 total. The thing that seems to slow me down the most is cleaning the case and engine covers out and removing the old gaskets to replace with new ones. If you aren't very mechanically inclined or if you don't have power/air tools I would probably figure on 7 to 8 hours.
@@FourwheelerDoctor Ok thank you thats good to know. I want to rebuild my 97 recon because there can sometimes be a grinding and clunking(?) sound shifting up to 3rd and 4th. What would you say is the most difficult part for a first timer? And also if you have any ideas why it might grind that would be helpful as well.
@@AndouilleSlim I'm not sure what that may be. Could be a bent shift fork or could even be worn clutches. I think the hardest part for a beginner would either be getting the transmission back together or most seem to struggle with the timing. A manual would help both tremendously.
My friend wants me to replace the valve seals on his Honda 250EX. I have been watching some of your videos and they are very good. The only problem with this 250EX is the valve seals. My question is, is it possible to replace the valve seals without taking the head off? I have replaced valve seals on several cars. I just don't want to take the head off if I don't have to. Thanks
If you have ever done a car while leaving the head on then you can do it on the ATV. You will have to come up with some way to keep the valve up as you take the valve spring off just like on a car. In all honesty it is just as simple to pull the head. You will not have to deal with any timing since the cams are in the bottom ends on the 250.
@@FourwheelerDoctor I usually take the spark plug out and hook my air compressor up to it to keep the valves from dropping. It's probably like you said, to be easier to just pull the head.
That will work but it's still pretty simple to just to pull the head. Good luck with it.
@@FourwheelerDoctorIt looks like I am gonna have to replace the piston and rings to get it to quit smoking. I think you said you put a .025 oversized piston and cleaned up the cylinder walls. Where you able to do that with just a cylinder hone or did you have to have that bored out? Also this 250 EX I'am working on do you think it being a 2001 I should replace the cam chain also? Thanks very much for your knowledge and help.
I had to have it bored and it's probably a good idea to go ahead and replace the chain while you are in there.
Deck screw lol yeah baby ill take that one thx
Where do you live because i need you to help me fix a four wheeler or can you help me
South Carolina
Never showed cam assembly
24:40 in is the cam install.
my shifter wont stay in motor have the right bolt
The bolt that holds the shifter in has a little nipple on the end of it. It looks different than any other bolt in the motor
Sentrifugal clush replasament four weler closhes
Hey you need to focus and put that camera on an easel and just let us watch you do it
good video but you forgot to clean the motor
I get the inside clean but usually don't mess with the outside. Most of the ones I work on are mud riders so they are right back dirty again after the first ride. But If you do want to clean one, a pressure washer and some etching rim cleaner will do wonders on the aluminum
I'm getting dizzy 😊
DOC, ILL PAY YOU $500.00 OVER WHAT YOU NORMALLY CHARGE FOR THIS SERVICE, IF YOU WILL PLEASE DO THIS FOR MY RECON ENGINE. WILL YOU DO IT FOR ME? I AM IN GEORGIA AND CAN DELIVER THE MOTOR TO YOUR HOUSE OR I WILL SHIP IT TO YOU. TAKE AS LONG AS YOU NEED TO GET IT DONE. THE ATV HAS SENTIMENTAL VALUE TO ME AND IM WILLING TO PAY A PREMIUM PRICE TO GET THE MOTOR TORN DOWN AND SEE IF ANYTHING NEEDS TO BE REPLACED. LET ME KNOW SIR. THANK YOU
Where are located in Georgia?
@@FourwheelerDoctor Near Atlanta. Have truck will travel!
I’m located in Madison ga. I’m needing some work on mine as well
I just picked up a 2001 250 recon she's stuck I neutral?? I'm about to pop the front off I'm hoping to fix it myself. But the header cylinder piston top block and rockers are trashed any advice
No telling what may have it stuck in gear. But if you pull the front cover off you'll probably find the problem. As far as the cylinder and head goes you can usually pick up used parts or new parts up on eBay at a very reasonable price so probably wouldn't be much to rebuild it.