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post #1 of 8 Old 02-04-2019, 12:41 AM Thread Starter
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Honda 250ex Issues

I bought a 2002 honda 250ex sportrax a few years ago and about 4 months ago we adjusted the valves because they ticking very bad then a few days ago it started to shutoff when it was shifted into gear unless I hit the throttle very quickly, if anyone nod what the problem is or has had a similar problem please respond, I do not that much about four wheelers.. please HELP
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post #2 of 8 Old 02-04-2019, 01:49 PM
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First I have to ask what was the valve clearance before the valves were adjusted and what clearance did you set them at. Second, did adjusting the valves get rid of the tick?

Most normally in overhead cam engines, the valves have to be be adjusted to increase the clearance - the valve faces and seats wear faster than the cam and rocker arms and the clearance decreases. Most ticking is generated by the cam chain and the piston.

My first guess is you do not have enough valve clearance dropping the compression slightly and making it easier for the engine to stall.
Second guess is the idle is simply too low.
Third; the clutch is not adjusted properly.
Fourth; the engine is not warmed sufficiently before starting to ride - should idle for about 5 minutes when the air temp is over 50 degrees - 10 minutes when the temp is under 50 degrees.
Last; the oil is too high a viscosity (should be 10w40 in the midwest, 20w50 in the southern climes and 5w30 in the northern climes) or is not a JASO rated oil. JASO rated oils are approved for use with wet clutches. Standard automotive engine oil can damage wet clutches.

Let me know more.
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post #3 of 8 Old 02-04-2019, 03:31 PM Thread Starter
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I do not know what the clearance was before we adjusted the valves but it surely needed it, it was ticking very badly, after I adjusted them it still ticked for about 3min before warming up we adjusted the clearance to .13 mm, the oil is oem Honda oil but I will look into the rest of the suggestions thanks for the info.
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post #4 of 8 Old 02-04-2019, 06:54 PM Thread Starter
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I changed the oil and adjusted the idle now it just bogs down when put in gear but it doesn’t stall out I cannot adjust the idle or air to fuel mixture screw enough to keep it from bogging down, maybe the carburetor is clogged up?
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post #5 of 8 Old 02-04-2019, 07:05 PM
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Changing the air fuel screw would not improve the situation - I think it's just drag between the clutch plates - how much free play is there at the clutch lever? Should be about 1/8 inch - less could cause the clutch to slip and more just decreases te distance between the plates when the lever is pulled in to release.

Did you get GN or HP oil? And what viscosity 10w40? Either oil is approved for use in your engine.
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post #6 of 8 Old 02-04-2019, 09:23 PM Thread Starter
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I bought GN4 oil and if you mean the clutch lever that’s usually mounted on the handlebars this four wheeler doesn’t have it Honda started putting reclusive clutches on the 250ex in 2006 this is a 2002
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post #7 of 8 Old 02-05-2019, 01:54 AM Thread Starter
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Thanku for the help I took apart the clutch and the centrifugal clutch was actually broke there was metal chunks and shavings inside the cover I will replace the clutch and hopefully this will solve the issue and the metal shavings/pieces will not effect the motor I cleaned it out very well so keep your fingers crossed
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post #8 of 8 Old 02-05-2019, 01:59 PM
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Quote:
Originally Posted by Honda 250ex Addict View Post
I bought GN4 oil and if you mean the clutch lever that’s usually mounted on the handlebars this four wheeler doesn’t have it Honda started putting reclusive clutches on the 250ex in 2006 this is a 2002
Quote:
Originally Posted by Honda 250ex Addict View Post
Thanku for the help I took apart the clutch and the centrifugal clutch was actually broke there was metal chunks and shavings inside the cover I will replace the clutch and hopefully this will solve the issue and the metal shavings/pieces will not effect the motor I cleaned it out very well so keep your fingers crossed
My error - I didn't check before advising - part of the problem with cyber diagnosis is the inability to see each unit - if the quad was in my possession, I could have seen that it was of the 3 clutch design and not the standard hand operated variety.

However, your wheeler does have a manual clutch in addition to the centrifugal clutch and the sprag clutch. The recommendation for free play on the manual clutch still pertains, but is set with the adjuster screw in the cover over the clutches.

As you operate the shift lever, the manual clutch is released by an internal mechanism rather than a cable and lever. Too little play and the clutch may slip causing the clutch to overheat and eventually fail. Too much play and the clutch will not release fully causing the clutch to drag which in turn causes hard shifting and engine stalling.

You may utilize the manual clutch by controlling the shift lever - practice operating the shift lever by shifting either up or down and holding the shift lever. As long as the lever is held either fully up or down, the clutch is held in release and no power is transmitted to the rear wheels. This method is handy when you are negotiating a difficult obstacle and want to keep the engine speed steady while feeding power to the rear wheels.

The sprag clutch resides in the centrifugal clutch hub behind the clutch shoes. The sprag clutch provides engine braking and allows for the ability to push start the vehicle if necessary.

Glad to hear you found the problem

BTW, the same centrifugal clutch was used in all the following models:

1987 TR200 A - CLUTCH
1987 TRX200SX A - CLUTCH
1988 TRX200SX A - CLUTCH
1990 TRX200 A - CLUTCH
1991 TRX200 A - CLUTCH
1991 TRX200 AN - CLUTCH
1991 TRX200D A - CLUTCH
1991 TRX200D AN - CLUTCH
1987 TR200 A - CLUTCH
1987 TRX200SX A - CLUTCH
1988 TRX200SX A - CLUTCH
1990 TRX200 A - CLUTCH
1991 TRX200 A - CLUTCH
1991 TRX200 AN - CLUTCH
1991 TRX200D A - CLUTCH
1991 TRX200D AN - CLUTCH
1992 TRX200D A - CLUTCH
1992 TRX200D AN - CLUTCH
1993 TRX200D A - CLUTCH
1993 TRX200D AN - CLUTCH
1994 TRX200D A - CLUTCH
1994 TRX200D AN - CLUTCH
1995 TRX200D A - CLUTCH
1995 TRX200D AN - CLUTCH
1996 TRX200D A - CLUTCH
1996 TRX200D AN - CLUTCH
1997 TRX200D A - CLUTCH
1997 TRX200D AN - CLUTCH
1997 TRX250 A - CLUTCH
1997 TRX250 AC - CLUTCH
1998 TRX250 A - CLUTCH
1998 TRX250 AC - CLUTCH
1999 TRX250 A - CLUTCH
2000 TRX250 A - CLUTCH
2001 TRX250 A - CLUTCH
2001 TRX250EX A - CLUTCH
2002 TRX250EX A - CLUTCH
2002 TRX250TE A - CLUTCH
2002 TRX250TM A - CLUTCH
2003 TRX250EX A - CLUTCH
2003 TRX250TE A - CLUTCH
2003 TRX250TM A - CLUTCH
2004 TRX250EX A - CLUTCH
2004 TRX250TE A - CLUTCH
2004 TRX250TM A - CLUTCH
2005 TRX250EX A - CLUTCH
2005 TRX250TE A - CLUTCH
2005 TRX250TM A - CLUTCH
2006 TRX250EX A - CLUTCH
2006 TRX250TE A - CLUTCH
2006 TRX250TM A - CLUTCH
2007 TRX250EX A - CLUTCH
2007 TRX250TE A - CLUTCH
2007 TRX250TM A - CLUTCH
2008 TRX250EX A - CLUTCH
2008 TRX250TE A - CLUTCH
2008 TRX250TM A - CLUTCH
2009 TRX250TE A - CLUTCH
2009 TRX250TM A - CLUTCH
2009 TRX250X A - CLUTCH
2011 TRX250TE A - CLUTCH
2011 TRX250TM A - CLUTCH
2011 TRX250X A - CLUTCH
2012 TRX250TE A - CLUTCH
2012 TRX250TM A - CLUTCH
2012 TRX250X A - CLUTCH
2013 TRX250TE AC - CLUTCH
2013 TRX250TM AC - CLUTCH
2013 TRX250X AC - CLUTCH
2014 TRX250TE AC - CLUTCH
2014 TRX250TM AC - CLUTCH
2014 TRX250X AC - CLUTCH
2016 TRX250TE AC - CLUTCH
2016 TRX250TM AC - CLUTCH
2016 TRX250X 3AC - CLUTCH
2016 TRX250X AC - CLUTCH
2017 TRX250TE AC - CLUTCH
2017 TRX250TM AC - CLUTCH
2017 TRX250X 3AC - CLUTCH
2017 TRX250X AC - CLUTCH
2018 TRX250TE A - CLUTCH
2018 TRX250TE AC - CLUTCH
2018 TRX250TM A - CLUTCH
2018 TRX250TM AC - CLUTCH
2018 TRX250X A - CLUTCH
2018 TRX250X AC - CLUTCH
2019 TRX250TE1 AC - CLUTCH
2019 TRX250TM1 AC - CLUTCH
2019 TRX250X AC - CLUTCH

Last edited by Here 2 help; 02-05-2019 at 02:04 PM. Reason: Added content
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