Alright 250ES/SX motor gurus..... I need help...

[Thorpe]

Developed a strange shifting issue with my 85 ES after plowing the last big storm... All the gears are there, no strange grinding or anything of the sort, new clutch installed a little while back, good oil, and the shifter pawl is tight on the shaft... There, we will rule out all the common issues. The thing I have developed is difficulty getting into first. From neutral, I have to lift way to the very top of the shift pawl's throw, to get it into gear... Sometimes takes 2-3 attempts. After that, all the gears are totally normal to get into. Just from neutral to first can be a p.i.t.a.... Anyone got any ideas?

[cattle-dog]

i just fixed one for a friend over the summer that ha a simular problem, take off the shifter and remove the side cover it will come off with a little moveing around its a tight fit. there is a stud/pin that screws in to the blck that sometimes brakes off from stress and lets the fork move around making it hard or impossible to shift its actually a easy fix if this is your problem. cattledog

[Thorpe]

Awesome... I will check it out... Thanks cattle-dog!

[MudBug]

I have a similar problem, but going from 1st to 2nd. It gets to be a PITA when taking off...

[skidoo99]

i just fixed one for a friend over the summer that ha a simular problem, take off the shifter and remove the side cover it will come off with a little moveing around its a tight fit. there is a stud/pin that screws in to the blck that sometimes brakes off from stress and lets the fork move around making it hard or impossible to shift its actually a easy fix if this is your problem. cattledog

this happended on one of my sx motors. someone had previousally welded the whole corner piece back in yet it wasnt the best weld and it broke again. ended up splitting the cases and using another case half

[Thorpe]

^^^ Whole corner of what?

[skidoo99]

this is what my case looked like. is this what you meant cattledog?

[ShaneNP123]

I fixed an SX with the problem, the mentioned stud backed out, locking the bike in reverse

[cattle-dog]

yikes !!!!!!!! thats the pin wow man what a mess if you need a good case i know someone who has one cattledog

[Thorpe]

Wow... whoever did that repair, PUT THE WELDER DOWN!!!!

That pin, just replace, and back in business? Whats the function of that pin? Is that pin part #21 in this link?

http://www.bikebandit.com/houseofmotorcycles/1985-honda-motorcycle-atc250es/o/m1902#sch9401

[atc500x]

Same probleme solved with the same solution on my SX last year

[bcredneck]

this exact probem is why i got my big red so cheap it will slowly get worse untill it starts goin between gears and then stops shifting compleatly all it was was the little bolt that holds the star shaped gear to the shift drum it took me days to figer that one out i damb near gave up

[cattle-dog]

the shift fork rides on it , its a common problem with a easy fix

[cattle-dog]

yes part 21
Wow... whoever did that repair, PUT THE WELDER DOWN!!!!

That pin, just replace, and back in business? Whats the function of that pin? Is that pin part #21 in this link?

http://www.bikebandit.com/houseofmotorcycles/1985-honda-motorcycle-atc250es/o/m1902#sch9401

[Thorpe]

Awesome... Thankyou again cattle-dog! Less than $10 from my local Honda dealer... Cant beat that with a stick!

[skidoo99]

yikes !!!!!!!! thats the pin wow man what a mess if you need a good case i know someone who has one cattledog

thanks but i already fixed with another case from a motor i had layin around. some pretty messy welding huh?

[Thorpe]

Not entirely sure we can call that "welding"...

[bcredneck]

if part 21 dont help my problem was part 8 it wasent broke just lose

[Thorpe]

113644Cattledog... You were 100% spot on...

[swifty]

is this bolt pictured above on the clutch side?

[Thorpe]

No... Stator side.

[Silverado]

I think I am going to start making a database for problems and solutions with the 250sx bikes....something of an Ultimate trouble shooting guide

[Thorpe]

^^ Good idea! SX/ES database....

[MudBug]

I bet it backed out real easy huh? they vibrate loose, the looser they get the more likely they are to break. I had one go in my turd 250es

[Silverado]

Ok I am starting to make it , i am also going to have all those explosion pictures with the parts and part numbers in an easy access format for a computer not have to have it online every time. you know something you can print out into a manual format or put on your laptop

[cattle-dog]

yep its not allways a hard fix lol. usually the threaded end is loose just as mudbug stated and it comes out easy. make sure to seal the case up dont want water in there cattledog

[Thorpe]

Drilled a hole in the bolt, tapped a torx bit screwdriver in lightly, and backed it right out...

[Silverado]

Hey Thorpe. Help me out. When I am look at a page like this



http://www.bikebandit.com/houseofmotorcycles/1985-honda-atc250sx/o/m1913#sch6423


Are they JUST bike Bandit part codes or is the small number different from the bigger font number ?

[Thorpe]

Must be BB codes... Bike bandit calls this part (21) #2693251 (7280669-001)

http://www.bikebandit.com/houseofmotorcycles/1985-honda-atc250sx/o/m1913#sch8216

Honda codes is #24652-HA0-000

http://servicehonda.com/look-up-parts/03