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2001 Honda Recon TRX250 Cracked Engine Case

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I have a 2001 Honda Recon TRX250 which I am basically rebuilding the entire machine with new parts (a project bike). The two head bolts broke off flush with the engine block so I carried it to a machine shop. The guy calls and says everything went good but the engine cracked out and around one of the bolt holes and he said that he could “doctor” it up. I’m a small engine mechanic by trade and have never came across this type of predicament because the head as we all know has to sit perfectly flush on top of the engine block. My question here to anyone in the know would be... Is it possible to “safely” doctor up such a delicate place on the block or case should i say and without fear of having issues with blown gaskets and/or any sort of problem at the site which would require a new case. I realize they are in two pieces and i could get away with buying one side, but I’m trying as most folks do to get away with spending less. Any feedback would be much appreciated.

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Nothing like a project bike !!! Welcome to Quadcrazy @Repair, think about how deep you are into this project. Would you really feel 100% comfortable knowing that the case is “doctored” up? Between the constant heat and cooling process which = expansion and contraction, I don’t think it will perform very well. Maybe in the beginning but not for long.  

I’m sure you can find a casing somewhere.  My personal feeling is..... Im wrapping up my 6th project and I asked the questions to a few friends on this site in particular about what to do and where to save and where not to try and save. Even if it meant holding up my project for a few weeks to find a few bucks. The end result was so much better. And the answer I think here is brother “doctor up” something that’s not that deep! Not the heart of the engine. 

Good luck.

Post some pics if you can we love to see progress photos.  

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It depends   on the  "cracks"  and what   is needed to  "doctor  it up".  If it  needs welding and re-drilling of the  head stud  hole ,  properly   annealing afterward  should  leave  it in  good stead.. The real  question is  it  it  cheaper, and does the  machine shop  have  a  good reputation for  warrantying their repairs.You  could  get that  one repaired, but  you  might find a good replacement  cheaper, and not worry about a repair failing.


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Thanks for the replies and the input. I was leaning more to having to put more money into for a better end result so now I do believe I will start saving. I will post pictures as soon as I can. I will be getting the engine back this week, but I will start working on it then and posting pictures. Again, thanks for the replies.

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Topic moved to Honda ATV forum and ATV info added to topic title. 😃

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Please explain how to get these gears along with the crankshaft timing correct. I know the notch on the cam is to line up with the mark on the case but at what positions do the crankshaft and Oiler need to be at when the camshaft mark is lined up correct.... any feedback would be awesome because this here is the last step i have on this four wheeler.


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