Gwbarm

Iv just got to locate the other gear original honda gear its also unavailable. Strange that it would be so different.

I dont know of any cable on the 2000 there is only the footshift no handshifter

Good luck! I will be curious to see what you find.

Thanks for the Tip Mech, i think it worked Honda4514HShopManual.pdf

The one on the right is the one that was in it. Even the teeth have a different arcitecture.

Oh, I missed that, you got to go into the bottom end, that could end up being a big job and get expensive if the crank is bad.

I will try that again, when i tried it the first time it wanted to print the whole manual

Caltric is the one i bought before i found the honda gear they are really identical with 18 teeth i havent seen the set you are talking about that might be it. I did bring both bypass gears back with me the one that was in the bike and the new caltric, i will get some photos later and post so you can see the difference.

Did this just happen or has it been troublesome all along, i have the opposite trouble with mine its very hard to get into reverse but i rock it and its hard to do sitting on it so i get off and move it back and forth while shifting and it finally goes in.

Looking through the service manual there is an ignition relay looks like a small CDI, i just have to find it not visible so it must be under the iinstrument panel.

I think you are correct does look like worn rings. Good luck with the rebuild.

Im not with the bike now i will be going back in a couple of weeks i should have written down the vin and engine #s.

Sorry for the poor quality of the schematic i was afraid that might happen

Not high on my priority list , but found a little time to mess with it. Still no spark cant really get to the coil without pulling the engine or cutting out the battery tray its welded in. I read the instructions in the service manual and decided not to do any of that. It didnt make sense to me to unplug the red black wire from the coil then it doesnt get power. It has no CDI but listed as a transistorized coil pack. Instead i decided to put 12 volts directly to the coil still no spark. To my surprize i put everything back together and it was sparking good. Started it on starting fluid several times and said im good to go. Tried it 15 minutes later no spark. So i decided maybe theres a capacitor in there that i charged up by putting direct voltage and it ran out, so that tells me no voltage is getting to the coil. I should have checked that first. Below is the troubleshooting chart and the wiring diagram, any thoughts.

Thats the one i got the 43/18 tooth and wouldnt fit and the one that came out was 43/14 tooth cant find it i think it was from another bike and was replaced along with the other gear that it mates with. The one that came out is pictured in #1 .

Finally got back on the Honda TRX 250. Got the starter in put the gears in and the cover wouldnt fit back on, took the old gear that came out of it, thats the starter bypass gear, and compared it with the original honda gear and the inner ring of teeth were different. The gears that meshed to the starter were the same but the inner gear that actually turned the engine was different, the original honda gear has 18 teeth for that year model and the one i took out has 14, i looked and looked and cant find one with 14 teeth from any model around that erra. It appears at some point a different gear set from what is called for was installed not sure what or why, im sure it was probably an aftermarket replacement set. Any insight .

The start stop switch does usually a black with white wire.

OEM or aftermarket.

Check start button operation and wiring to soloenoid.

Maybe loosing spark check for loose connections.

Did it start before the nrw plug

Took afew shots to give an idea of what i was referring to:

I did find this one a little newer but may help. d68a92.pdf

Thats good i would think that is not your problem.

I have been looking for one havent found one yet. Plenty you can buy but no free ones.