My Winter Project- Honda 250sx

[Flyingw]

Nope, the shift shaft is shot. You need a shift lever and shift shaft.

[Flyingw]

Here's a good one

http://www.ebay.com/itm/Honda-ATC-25...8ab0fd&vxp=mtr

Shift lever

http://www.ebay.com/itm/Honda-ATC-25...3965a1&vxp=mtr

[Flyingw]

Here's another good one cheaper

http://www.ebay.com/itm/Honda-250-SX...p2056016.l4276

[Lantz]

To get an accurate compression test, the engine needs to be at operating temp, choke off, throttle wide open. Doing it with a cold motor usually shows a low compression.

Yea I figured it would be low since the engine wasn't hot. But I didn't have much option since the engine is out. I just wanted to get an idea for the compression, it didn't seem to bad for the engine being cold?

[Flyingw]

Another shift lever

http://www.ebay.com/itm/Honda-ATC250...p2056016.l4276

[UPNATM]

The splines on your shift shaft look pretty boogered up. I would suggest trying to find a new one. It's been discontinued through Honda, but there is actually a pretty clean one on ebay right now. There are also a bunch of shift levers on ebay as well. If you don't want to go the eBay route you may also have some luck by posting an wtb add in the classifieds here.

Edit: lol, dang while I was typing Jim beat me to it.

Since you have to change the shift shaft it would also be a good time to check and or replace the shift pin if it happens to be broken, or become loose.

[Lantz]

I picked up a shift shaft on eBay along with a shift lever, and a gasket set. I got my carb back from Jim, it looks great by the way and I got the 350x lever on it. I'm goin to tear into the engine today, what should I be looking for when it comes to the shift pin?

[UPNATM]

I picked up a shift shaft on eBay along with a shift lever, and a gasket set.I'm goin to tear into the engine today, what should I be looking for when it comes to the shift pin?

Scroll down to the bottom of my page 2. I had to do mine a couple of months back. As you can see in the picture, mine was broken in half. Once you get the side cover off, and slide out the shaft, you should be able to see if its broken or not. I read up on a couple of threads, before I did the job, and found a post were Jim (FlyingW) said to lay the bike on its side, and that how I did it. It worked out great, and now shifts like a dream.
http://www.3wheelerworld.com/showthr...nd-build/page2

[Lantz]

A quick update, I have replaced the shift shaft, fixed the foot peg, fixed and bolted on a hitch, and put together a complete battery box that's now installed with a new battery. Jim (Flyingw) did an excellent job rebuilding my carb, it looks better than brand new. I tore down the engine while it was already out, the internals of the engine looked great.I went ahead and honed the cylinder, replaced the rings, and adjusted the valves. I have to finish putting the engine back together and get it back in the frame. Other things I have to do is get the steering stops set up, get the dash sorted out along with the rest of the wiring, and find a clamp for the air box.

[Lantz]

Can anyone recommend a good fuel filter? I found a couple on eBay, thoughts?

http://www.ebay.com/itm/140605766908...%3AMEBIDX%3AIT

http://www.ebay.com/itm/300981639625...%3AMEBIDX%3AIT

[UPNATM]

Can anyone recommend a good fuel filter? I found a couple on eBay, thoughts?

http://www.ebay.com/itm/140605766908...%3AMEBIDX%3AIT

http://www.ebay.com/itm/300981639625...%3AMEBIDX%3AIT

The top one is what I run on both of my sx's. Small, so it doesn't look goofy, and works good.
You can get them at any Napa, etc.

[Lantz]

Alright thanks I think I'll go with that one then. I've read good things about the sintered bronze filters but never used them.

[prairiedog14]

This is a nice project! I've been working on one myself.

[Lantz]

I just got back in from putting it all back together. The electric start doesn't work, but it starts when jumped. The kick starter doesn't return and just wants to spin. And it's leaking oil pretty good from the side gear case, it looks like someone tried to separate it by ing it with a screwdriver.

[dougspcs]

Sounds like this thing has it's share of issues..

You're gonna dump a boat load into the engine alone.

Hope your really feeling it for this old girl!! From a dollars perspective it'll be cheaper to find another decent SX and use this one for parts!!

But if a rebuild is what you're looking to do then have at at it..there are a lot of talented guys in here. FlyingW for example has mad skillz..I've seen his work and bought his rebuilt carb numerous times.

Good guy to have in your corner as you start this project!