Gwbarm

Look at the throttle plate inside the carb make sure it is not jammed open or stuck also check the cable make sure its not sticking.

Actually its getting close to winter here not much grass to cut.

I would take a closer look at the timing chain and gears, roll it around and look at all the teeth, and im sure you checked the flywheel key. Yes something else could have happened if it sheered off bolts thats a lot of stress on gears.

Getting closer got the battery tray installed back today, it is now removable. I was going to weld it back, but then if i have to remove it again be more difficult. Just like it never happened The holdown was missing going to fabricate that clean the rust off and then pressure wash the whole thing.

It is a nice design, you pull the fuel filter out the hole change it put it back, there are spring clips it clips into to hold it solid, the problem was the hose from the fuel pump was too short to let the filter come out the hole maybe shortened sometime in its life or maybe came that way from Honda dont know, but it is well protected. Im fairly good size 6 3 195 big hands and have gotten bigger working on engines all these years.

Thats great that it will shift through all the gears, thats correct it would be semi automatic.

Got the carb all cleaned up. Pumped fuel through the fuel lines to check good flow. Went to change the fuel filter and drain the tank and clean it out. Got to looking for the fuel filter finally found it . Down below the tank just like everything else a real pain to replace. There is enough room to get it out the hole but the hose is not long enough to pull the filter out the hole connect the new one and put it back in. There probably was when it was new, a little hose being cut off over the years, but just barely, all original honda hoses, there is access underneath, luckily i had some long handle hose pliers and got it back on. I replaced it with an original honda filter and it just barely goes through the hole with a little force. I really need to run some new hoses to get extra length but i didnt do that today.

Good call ! Those were my thoughts as well, it has been doing this for years but its never caused a problem its just annoying. I am very suspicious of the starter clutch(sprag) biggest concern is if that is what is causing the starter and bypass gears to shear off every few years i need to replace it. I think the one on the clutch side is working with no issues, but i do have to pull that side off to repair the kick starter.

Thaks Mech! It has been years since i have ridden this one and i think the ones that im used to riding are heavier and lower geared and also 4 wheel drive so i may not have noticed the rolling backwards . The noise that i hear during cranking and especially after you let off the starter button thats when its most prominant,i thought might stop once i replaced the al the gears. So something else is causing it.

Thats great you got it to run. You can take the choke plunger out of the carb if its stuck try some carb cleaner or WD 40 to free it up and get it out then you can oil the cable. You are well on your way, well done!

Finally got back to the 86 Honda TRX 250. Got the starter and the correct gears installed. Everything work great. But it still has this clunking noise when starting, once started everythings good, except it would only run on half choke, hadnt been run in a year and wouldnt start so my brother left gas in the carb, i powered some of my Berryman in the tank and in 15 minutes turned the choke off ran great. I hadnt riden this thing in years and i noticed a few thing when going up a hill if you let off the throttle it will roll back down the hill unless you apply the brakes. Also if it in in gear you can push it backward but not forward and i have no engine braking. So im not done yet, it was supposed to be an easy fix, i think the starter clutch is not working.

Sounds like you may have a head gasket leak.

That part shouldnt be too bad i would try to clean up the original carb if it is still an OEM carb, Mikuni or Kei Hin hopefully its not full of white powder that is the metal corroding down and sometimes actually destroys the integrity of the carb.

You can probably get it to run on the aftermarket carb by doing some adjustments, some times you have to adjust the throttle cable, it wont let the throttle plate go all the way back to closed to get full choke, also the choke plunger could be a little different, did you put the choke plunger that came with the aftermarket carb on or or you using the original one. With all that i think i would still clean up the OEM carb and use it i think you will get better performance from the original carb.

Yeah i was a little worried about the replacement coil i could see where the flywheel had been rubbing against it on one side. I usually dont, but i actually got a feeler gauge to make sure i had exact clearance between the coil and flywheel i usually just use a business card. My feeler guages werent long enough to reach both lobes of the coil so i had to do one side at a time and bend it into a curve to use.

Nice looking seat for the price and its made by Caltric, that is one of the aftermarket parts suppliers that i use and have been very pleased with their parts.

Got back on the honda yesterday got the new coil installed it is now sparking so i guess the transistors in the original coil was bad. Before i buttoned it all back up i vhecked the timing belt looked good the timing was spot on so all is good. Havent started it yet thought iwould go through the carb first. Pulled the carb off had a cute little Kei Hin carb on it. It would have never started the carb soloenoid was stuck it was stuck bad couldnt move it at all tried carb cleaner no luck PB Blaster nothing finally got it freed up with WD40, that amazing stuff, havent been using it much usually use PB Blaster. Pulled the carb apart bowl was nasty. Main jet was clogged, everything else was fairly clean. Drug out my ultrasonic cleaner and was looking around for something to use iin it i usually use simple green or royal purple or Dishwashing liquid i didnt have any so looking around i found this Not expecting it to really do anything at all i put a couple of ounces in a quart of 2 quarts of waterand was competely amazed this is right out of the cleaner. Nor bad i finshed up with Berryman the best i have ever used. I will have to say this is one of the cleanest carbs to come out of the ultrasonic cleaner i will use Mr Clean again

I did find this. May help! 7e5105.pdf

If the diff lock is sputtering more the more throttle you give it , it does sound like an electrical contact problem maybe a safety switch i would have to pull up a schematic to see, but for starters i would check all the electrical connectors associated with the diff lock and i will look and see if i can find a manual and take a look.

Most of the things you describe could be related to a low idle speed. You might try increasing the idle speed and see if anything changes. The diff lock takes more power from the engine, but it should not sputter, hard to diagnose without seeing exactly what is happening, does it get better when you increase engine speed. There could also be something in the diff lock that is not engaging correctly. There are cables that operate these things that might need to be adjusted. As far as the MPH and KPH there may still be something in the wiring that you put back together that is not exactly right. You might try killing the power to the display then power it back up and see if it reverts back to MPH. Like i said hard to diagnose with actually being there but these are the things i would check.

Not seeing the condition i would estimate 1000-1200.

Welcome back! Sorry to hear about your illness. Not really familiar with Ross River fever. It sounds like your getting back to your quad, getting the fuel system cleaned out and get it running good, checking for good spark and compression are good first steps. Good luck!

Those tires look great, real beefy looking i like them. Nothing wrong with Temu i have actually been impressed with a lot of stuff i have gotten from them. I only asked because i am looking at buying a set right now, i have been looking at Kenda Beaar Claw and Sun F, i will now look at these. Thanks for the info.

The last 2 batterys i have bought have been Weze battery. I did not know antyhing about them they were just the cheapest on Amazon. They have been excellent so far no problems. I usually only get a couple of years out of a battery, and less on lawn and garden batterys, occasionally you will get a good one i just replaced one that was 9 years old but it had been a little troublesome for the last couple of years. Batterys just arent made as good as they used to be. I will be curious to see how the Wese batterys hold up over the next few years. They get good reviews.

You will have to post some photos, which tires did you end up going with.