Gwbarm

I like going back standard size if I can, I like keeping things as close to factory as possible, no reason really, but that’s your decision not going to make much difference either way.

Good idea to go ahead and put new rings in it cylinder should be fine.

That’s good now he knows how it works, I have a granddaughter she is 5 and whenever I am over fixing something for them she is right with me learning how things work, makes me proud, she has an interest at that age.

Right Mech sometimes the hammer gets it to going but it still needs cleaning up

Thats great you are still going on the 350, i was hoping you would, if he has interest get him involved also, great memories of working with Grandpa on the honda. Things you think are meaningless at the time go with them the rest of their life. I know they did for me. You hooked up the starter exactly right with the jumper , just make sure you are getting a solid ground. Make sure the engine is free and not locked, if thats good, and it still clicks you can tap on the starter lightly with a hammer sometimes it will go, just corrosion and brush dust gets in there. If still clicking you caan take it out and see if it spins on the table with the jumper.

I would run them also, it not like they are highway rated anyway, rubber does get harder and slicker as it gets older, so if you are doing a lot of rock climbing and hitting stumps you might reconsider, but that kind of riding plays havoc on new tires also. So yeah i would run them, but i wouldnt try to break any speed records.

I think i have it figured out, the half moon one goes on the 2005, 2006, 2007 models. The other goes on the 2002,2003,2004 models, but there are still throttle cable differences in the 2002, and the 2003 and 2004 models, nort sure why that is yet. Of course i would pick the wrong one to go on there, i had both and had not paid the throttle hook up much attention. I guessed the half moon one only because the Big Bear i was working on had the half moon design and it was a 2000, so i came to the logical conclusion that that was the older design, because like you said Mech the parts places dont show you that detail.

That little 250 is a really good engine, enough power, smooth running, light weight and easy to steer. Hopefully fresh gas and carb clean will get it going.

Got the 2004 carb out today to take a look at the throttle cable connections. They are definately different from one year to another. The one on it now was supposed to be from a 2003, but i suspect its from a later model. As you can see in the photo the one closest to the camera is supposedly for a 2004, this is what i was told when i bought them and the one attached is 2003 which has a half moon cable connection, the other one does not. Interesting so many variations between years. I was just looking at a new one online for a 2006 and its cable hook up was just like my 2004, so maybe my theory is flawed and the halfmoon one was from 2003.

You have replaced the major components, two other things come to mind as to what is causing this, maybe a bad ground or pickup coil in the stator assembly. You could try unplugging the wiring from the pickup coil. and check for corrosion clean them up good and see if that helps.

Any of the OEM online parts houses can get them for you, i just checked rockymountainatvmc they have the OEM decals not terribly expensive.

Did a little work on the Eiger today, decided to install a freshly rebult Kei Hin original carb, on it, got it on no problems, hooked up the throttle cable, then the problems started. The cable is too short, dont know if its an aftermarket cable, or not. I next went to the adjustments, it was adjusted to the max for the aftermarket carb that was on it. Got it adjusted all back to really no adjustment and it was still holding the throttle open a little maybe 1/4 inch. The video shows it running and it runs better than any junk machine i have had in a while, i was very impressed with it. It is idling too high and i didnt even have the throttle hooked up, so i need to get that figured out, and with the adjustments all the way to 0, with cable hooked up it holds the throttle open even more. After doing further reasearch i found the carb that i put on it is a 2003 and the 2003 carb has a different cable # than the 2004, not sure if the carb is different internally, or if different because of frame differences. Also the 5,6, and 7 models also uses a different throttle cable, go figure, they all look alike. I have a 2004 carb i havent rebuilt yet i guess i will try that one, or either get a 2003 cable. IMG_4280.mov I did look in thee throttle housing to see if there was anymore adjustment there and i had it all the way. Im sure i can work the high idle out once i get the cable situation sorted out.

Thats interesting Kei Hins are generally tuned perfectly from the factory, maybe because of the snog requirments they put on these days make them a little leaner, my only concern might be how does it run at high speed and warmed up. Sounds like you have it figured out, but 115 is a fairly large jet for a 270, but if it works good thats all that matters. Thanks for sharing your reasearch.

You just match up the two dots, you can see that on one gear has the spot in the valley and the other gear does not, just match up the two spots and you are good to go. in the

Mine is a little sloppy also i adjusted most of the slop at the linkages out, my slop seems to be where the shifter slides onto the pivot rod attached to the frame, yes a hand shifter would take all that out going directly to the trans, i need to order one and try it. Thanks for the info.

Sound like you got a good one post some photos.

Good you got it running floats probably stuck

Thats funny, never ran across a thumb heater, interesting, high tech for 2004.

I had a similar problem when i first joined, you were only allowed so many per day, didnt try for a while after that and then had no problem. I do get manuals that are hard to find at manualslib.com.

Good you have help

Correct it will start in gear when the brake lever is pulled, that how i was able to use it today, and then it got stuck in reverse. So it appeaars its not quite finished yet, but maybe one of this age and abuse level is never finished.

Thanks! I missed that, rathar annoying to get to especially since i just changed the oil ,again, i am going to check the wiring good because i did get it to come on once yesterday, its been troublesome since i have been working on it, i would get it in neutral and then it would come on 15 seconds later.

Took the Big Bear out for a ride today did very well but did have a major issue. Engine ran well carburetor did exceptionally well after i turned the choke off. I rode it probably 30 minutes it continuously wants to get stuck in reverse i can usually get it out but this last time it wasnt having it, i had to get off and play with it for a while, rougher than i like to to get it back to first, anyone else ever have this problem, this is my first Big Bear so nothing to compare it to. Im still trying to locate the neutral switch light still not working i went through the manual and never could find the location im sure its there somewhere i just missed it. Most of these i have worked on just has a little nub sticking out of the engine housing with a wire on it, this one doesnt have that, it must be inside the case.

You have been busy, glad you got it running without spending any money, cylinder looked like it would cleanup well. Its good you got the rings free without breaking one, thats what generally happens to me.

According to the laws in my state no ATV can be made street legal, no turn signals, no approved tires and no seat belt. Desert should be OK.