TRX 250 no spark

[Rex in OTZ]

My daughter borrowed the honda to viset a friend at camp, she was long over due to be back so I went looking for her, found her broke down along the trail quite a ways from town, she was still trying to trouble shoot it herself, We determined it had gas but dident act like it had any spark so we towed it home and next day put in a new sparkplug and tried kick starting it as we never use the electric starter, still it wouldent start, Useing my Fluke multimeter I checked the ignition and kill switches, Ohm'd the ignition coil and CDI everything checked ok according to the Honda manual, then I Ohm'd the ignition pulser coil and it was bad, last night I pulled the Lt side cover off to get at the Pick up module and discoverd when removing the electric starter its drive splines were all galled off, the spur gear the starter rides on was missing almost all ther teeth, the little bits of hardended teeth went into the rotor and did the muncha matic on all related rotating parts, now I have to find a suitable rotor and stator and new modules pluse see what metal contaminants i can flush from the case.
I checked on-line at BABBITS they have the parts I need but they shure are spendy.
I know of a village to the southeast that has a couple dead TRX 250's inside the fence of the city dump that may have suitable parts.

[Rex in OTZ]

Stopped by our local  Kotzebue Alaska hardware store, these guys stock some basic honda parts, I bought a after market flywheel puller for $16 and was in the disassembly business, slipped a 13/16 socket on a 3/8 breaker bar with a couple love taps of a rubber mallet, the fly wheel slid right off.

This is what happens when the starter drive spur gear drops some teeth down on the flywheel which loves magnetic stuff like that as one can see it scuffed the factory finish on the flywheel and knocked all the sharp corners off the stator and scuffed up the pick-up's to the point they quit working.

In the old days I had a simular problem with Honda Big Red ATC 200's the recoil starter on the side would eventually crack a little and a piece would get sucked up by the flywheel magnet and do the veg-a-matic on the pick-up-coils on them 3-wheelers.

Added a picture of the reverse side the rotor to show the one way starter clutch fingers, they do look like rollerbearings but not.

[Rex in OTZ]

The 250 was back up, Yesterday afternoon my oldest daughter and I reassembled the 250 with salvaged parts form another village, My daughter helped cut a new side gasket form a old calinder back and used liquid gasket, she changed the oil while we had it appart, got it all put together for a spin round the area, it ran great, took the kids and mutts out for a jaunt out behind town and had a great time, returend home happy with its performanced, parked it right where we usally had for the last 7 years, this morning its gone, sombody unhitched the trailer and pushed it down the dark part the street and attempted to hotwire it, all they did was mess up the wireing and ruin the switch found it all gutted out wires hanging out the console lucky the key'd barrel was sitting on the seat seems they dident know what they were doinhg as they only disconnected the electric start portion not the kill switch, so its dead again for a little bit till I somehow fix the switch or buy new,
I was wondering if can I solder the wires back on the back the switch without dissembling the switch?
I guess I'll try anyway, its junk if I cant fix it so nothing to lose by attempting to solder it.

[Rex in OTZ]

I did find somthing of interest when I disembled my 1986 Honda TRX 250 shaft drive, the electric starter has its own set of starter clutch and gears, seems the starter tag's-a-along spinning while the engine is running eventually the starter drive will chip off teeth from the spur gear it rides on, in my case almost all the teeth had sheard off and dropped down causeing all sorts of mischief, the spare parts from the village parts Honda reflect this damage as well, the spur gear on that cover had 4 teeth missing and they were sucked down in the replacement flywheel as well, some minor scuffing but no real damage to flywheel and stator,  since its more reliable to kick start, I dont use the electric start, I left the spur gear out and reassembled, the electric start need's a new spur gear I'd have to buy and would be easy to install in the future if I want. so the for now the starter is just along for the ride to plug the hole in the crank case cover.

[hillbill]

well sounds like yu learned a lot if nothing else!i get a lot of parts for older wheelers off ebay. always someone parting one out on there if shipping to yu is a option.really stinks about someone trying to hoist it from you and makeing a whole lot more work for ya.i cant imagine someone trying to steal one that old.must of been some local punks out for a joyride.let us know how it turns out and what yu did with the switch.

[Rex in OTZ]

The manual came in handy was able to solder the switch, halfassed the wires back on the switch, now that they had torn off the wire support I had to use something else...3M 5200 boat hull sealant.
The ATV was running last night, needs a tune up with a different flywneel need to check timing may be a little off, I know it could use some good gas, I had some old lawnmower gas I dumped it for a go round the patch last time before the midnight riders messed with it.

In OTZ (pop3400) there are thieves but they are outnumberd by drunks,the OTZ cops let drunks free range all over the place, Talk about Job Security! They got that one down pat.

A drunk looking for a bottle after midnight will cover allot of ground looking for the next drink, any transportation just laying round being unused during there drunkin nocturnal forays not naild welded or locked up is public domain in there drunken eyes.

[hillbill]

good grief sounds like yu are overpopulated with roaming drunken neighbors.here in MO they fear our sudden applications of birdshot and buckshot too much to be wandering around in our yards.but then i live in a severely rural area.you mite think about a fenced yard and a large dog with a bad attitude?once yu get that trx finally figured out it should be very reliable since yu will of eliminated its weak point.

[Rex in OTZ]

Well the switch was salvageable I solderd the wires back on, had no problems, a co-worker related how her 2006 Honda recon had been hotwired & stolen last weekend, that makes 14 in town so far this month.
OTZ is not that Big. In the co-workers case the cops managed to nab a couple drunk teenage joy riders on it, they crashed it into a fence trying to dodge the cops, In jelly doughnut fashon they managed to nab the one too impared to escape(one that fell off the back) both turned out to be 14 yro boy's(wheres the parents?).
Still the thieveing continues, they must have buddies.
My 1986 Honda's ignition switch has 4 wires to it just like the Pictured 2006 Honda, a couple big power wires(Black and Red=battery power) and a couple smaller (green& Blk/w=ignition) wires, thieves yank the wires off the back the switch by hand.
All there really doing is breaking the ground to the ignition circuit, to pull start the rig, they use the handlebar kill switch to kill the engine.