My Winter Project- Honda 250sx

**Lantz** · 03-21-2014, 10:39 AM

The electric start doesn't worry me much its probably something simple, because it runs. I'm sure I can fix the kick start or live without it, once I get the electric start working.

Now, the side gear case is another story. Can I just pull that piece off, once the shaft is disconnected?

I'll post up some pics this evening.

**UPNATM** · 03-21-2014, 01:01 PM

Originally Posted by Lantz

The electric start doesn't worry me much its probably something simple, because it runs.

Check the switch. When I first got my SX running I had no electric start as well. After starting at the rear, and working my way all the way to the front I found it was just a bad connection on the switch. Took the switch apart, cleaned it up, and bam, started right up.

**Lantz** · 03-22-2014, 01:39 PM

Here's a picture of it all put back together.

**Lantz** · 03-23-2014, 01:46 PM

Well I got the oil leak all but fixed, insted of gushing oil it leaks a little when running and stops when parked. I got the electric start working (there was a red wire that wasn't hooked to the battery). I replaced the diff. cap today and the oil is more like brown sludge. How do I flush this out and what to replace it with, I would prefer something I can buy from an autoparts store. The kick starter is making a clicking noise. It doesn't return but still ratchets, and the kick starter wants to turn down when running. Is this something I should be worried about?

**Flyingw** · 03-23-2014, 04:37 PM

For right now, drain the diff and refill. Run it a little bit then drain it again and fill with Marvel Mystery oil and run it around for about 5-10 minutes at very slow speed or just jack the rear end up and let the motor turn the diff at idle for 5-10 minutes. Drain again and refill. Use 80/90w hypoid gear oil. Both oils are readily available at the auto parts store.

The kick starter is a whole different matter. The clutch cover has to come off. The book does not say how to install the kicker gear assy. There is a spring on the kicker, you have to hook the spring at the 6:00 position then you have to turn the kicker shaft CW to wind up the spring so the punch mark that is on the end of the licker shaft is past the 12:00 position then while holding the kicker assy, you have to drop the case side of the kicker in to the hole while meshing it with the idler gear then you can release the wound tension. Hard to describe but when the kicker is installed, the punch mark should be straight up at 12:00. I hate the SX kickers.

**Lantz** · 03-23-2014, 06:51 PM

Alright thanks, it seems like the shaft isn't disengaging. When running I can turn the kicker shaft back and it just turns back down.

On another note I cant get the 90* final gear drive to stop leaking oil. The 3 bolts were out when I got it, I read on here that those bolts shouldn't be removed?

**Flyingw** · 03-23-2014, 07:02 PM

Well you can take the bolts out but don't remove the side case gear assembly unless you are going to disassemble the tranny because the secondary shaft assembly is part of the tranny. The seal for the side case gear assembly is an oring. There is also a transfer boss tube with an oring on that. One of those two items is either defective or missing. It sounds like the entire engine needs to come apart.

**Lantz** · 03-23-2014, 09:06 PM

Thanks Jim for all your help, so it sounds like the engine has to come out to replace these o-rings? Other than these two problems (the oil leak, and the kick starter) its running great, It starts and runs good and all the gears are there.

This is where the oil was leaking out of the worst.

**Flyingw** · 03-23-2014, 09:23 PM

Ya, the tranny has to come apart to investigate the leak. No way around it.

**meatonastick** · 03-26-2014, 05:53 PM

I need to get myself a 250sx sometime, but around here even the hard-beaten ones are close to a thousand dollars, which is quite a bit more than i have haha. good luck on the project i hope it all comes together without too much trouble, but we all know how it goes.

**Lantz** · 05-11-2014, 09:28 PM

Well I pulled the right crankcase cover today. I discovered the thrust washer that sits on the back of the kicker shaft under the oil screen in the bottom of the crankcase. Is there any reason to remove the clutches as described in the manual? All the parts are there and in good shape. I'm thinking someone else disassembled the kicker shaft in the past and didn't tension the kicker spring?

**Lantz** · 05-13-2014, 08:32 AM

Well I got the kick starter all put back together, what a PIA. I was able to put it back together with out removing the clutches. Its still running great and no more clicking noise.

**Flyingw** · 05-13-2014, 02:33 PM

I agree, the ES/SX kickers are a huge pain to put back in.

**Lantz** · 06-02-2014, 10:50 PM

Yea, I sealed up the oil leak with some silicone. I wasn't about to tear it completely apart again. She doesn't leak a drop now. I also changed the oil in the rear and got the steering stop welded in. New brakes too, the rear brakes were shot. The front brakes still need some work, the caliper doesn't seem to be working right.

On another note we took a trip down to Hatfield and McCoy's about a week and a half ago. I rode the sx one of the days we were down there, and it ran great. The solenoid is only working about half the time but nothing that a piece of wire wont fix.

**lrharleyd77** · 06-02-2014, 11:07 PM

You will like the sx when you get it finished I have 3 of them and me and my buddies live them they will get you through about everything I have built about a dozen sx's so feel free to ask me a question if you run into a snag up I also have a few of these in parts

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