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Discussion Starter #1
Hey guys so long story short I bought an 01’ 250ex dirt cheap. It needs a trans, there’s a hole in the housing. Does the engine and trans share the same case? I’m going to assume I need all new gears too. I’ve been looking for a cheap parts quad I can yank the trans off and swap it but haven’t had any luck. Any info would be great!
 

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The engine and transmission share the same casting - several parts for the transmission are not available - you cannot 'yank a transmission off one and put it on another, you can swap engine/transmission assemblies - it will be best to find a used engine/transmission assembly either complete or just the lower end and whoever you get it from get a written guarantee that it is in good usable condition. Try powersportsnation.com - call them at 402-371-7002.

I compiled a list of transmission parts (not 100%), but a new transmission would cost over $1000 and some of the main components are no longer available - mainshaft and 18t gear are NLA
Qty​
Part Number
Description​
Price​
Total​
23211-HN6-000
(OBSOLETE) MAINSHAFT (15T/13T)
0.00​
0.00​
23221-HN6-000
COUNTERSHAFT (21T)
131.96​
131.96​
23411-HN6-000
GEAR (37T)
54.76​
54.76​
23412-HN6-000
SHIFTER
38.85​
38.85​
23413-HB3-000
COLLAR, SPLINE
54.40​
54.40​
23414-HB3-000
BUSH (22X8.5)
16.18​
16.18​
23415-HB3-000
BUSH (15MM)
13.87​
13.87​
23431-HN6-000
GEAR (29T)
57.98​
57.98​
23441-HN6-000
(OBSOLETE) GEAR (18T)
0.00​
0.00​
23451-HN6-000
GEAR (26T)
48.31​
48.31​
23452-HB3-000
BUSH (22MM)
16.18​
16.18​
23456-KA3-000
WASHER, LOCK
4.95​
4.95​
23461-HN6-000
GEAR (23T)
61.40​
61.40​
23462-HB3-000
BUSH (20MM)
16.18​
16.18​
23471-HN6-000
GEAR (26T)
59.49​
59.49​
23481-HN6-000
GEAR (23T)
48.56​
48.56​
23521-HM8-000
PLATE
4.53​
4.53​
23721-HN6-000
GEAR (32T/16T)
55.33​
55.33​
23731-HB3-000
SHAFT, REVERSE IDLE
20.29​
20.29​
23751-HN6-000
GEAR (31T)
59.00​
59.00​
90451-107-000
WASHER (15MM)
1.22​
1.22​
90452-HB3-000
WASHER (15MM)
6.80​
6.80​
90452-HN6-A00
WASHER (15MM)
4.64​
4.64​
90454-107-000
WASHER (20MM)
1.62​
1.62​
90455-107-000
WASHER A (20MM)
1.60​
1.60​
90457-HB3-000
WASHER (15X1)
2.53​
2.53​
90464-KE8-000
WASHER (22MM)
3.53​
3.53​
90601-329-000
CIRCLIP (22MM)
2.22​
2.22​
90605-200-000
SET-RING (20MM)
2.40​
2.40​
91001-HN6-003
BEARING (6202U)
11.24​
11.24​
91002-HE0-003
BEARING (S6205)
14.69​
14.69​
91202-898-003
OIL SEAL
7.62​
7.62​
95701-06014-00
BOLT, FLANGE (6X14)
0.80​
0.80​
96100-62040-00
BEARING (6204)
10.69​
10.69​
96140-62020
BEARING (6202U)
12.22​
12.22​
24211-HN6-000
FORK, FR. GEARSHIFT
48.87​
48.87​
24212-HN6-000
FORK
48.87​
48.87​
24213-HN6-000
SWINGARM, GEARSHIFT
48.87​
48.87​
SubTotal​
992.65​
 

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Discussion Starter #3
Thanks for the information that will definitely point me in the right direction. So if I understand you correctly the trans and bottom end share the same housing so if there’s a hole in the “trans” the entire housing would need to be replaced
 

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Here's the crankcase - as you can see all the parts go inside:
4330

Now there is a cover on the front and rear - are you sure the hole is in the engine case or might it be in one of the covers?
 

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Discussion Starter #5
i will have the quad home tonight, I’ll pinpoint the hole. I found a local guy that has a full swap (spun beating) with new clutches and miscellaneous other parts for $250
 

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I don't understand - spun beating? - I presume you mean bearing, but that still makes no sense - the bearings are all ball and roller - there no bearings to 'spun'.
 

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Discussion Starter #7
I don't understand - spun beating? - I presume you mean bearing, but that still makes no sense - the bearings are all ball and roller - there no bearings to 'spun'.
Sorry, still getting familiar with quad specifics. “Rod failure due to lack of oil” were the exact terms the seller used.
 

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Lack of oil will damage cam and rocker arms ahead of the rod - rod is a roller bearing and is mostly damaged by water and/or extended high speed riding with old oil or incorrect grade of oil, but there will be enough parts from two motors to rebuild one.
 

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Discussion Starter #9
Lack of oil will damage cam and rocker arms ahead of the rod - rod is a roller bearing and is mostly damaged by water and/or extended high speed riding with old oil or incorrect grade of oil, but there will be enough parts from two motors to rebuild one.
 

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Discussion Starter #13 (Edited)
I also got a Honda service manual with the purchase of the 250. Years listed on the cover are 2001-2004, the engine I’m suppose to pick up this Sunday for rebuild is an 05. Are they interchangeable?

I will have some time tonight to remove engine from frame and get a better look. I don’t know what would make that gear blow out of the housing. After looking through this service manual I am starting to get a better idea how this engine/trans combo is put together. It’s a split case, I hope the crack is contained to the transmission side.
 

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OK - I am not an expert engine swapper, but my investigation reveals:
The 2001 250EX front engine half was the same from 1997 to 2002
The rear engine half was the same for 01-02
The crankcase case gasket is the same for 97 to 2020

I'm pretty certain the 05 motor will install into the 01 frame, but internal parts from one may not swap to the other.

The good news is the crankshaft was the same 01 to 19, so the crank from the 01 can be used in the 05

I suggest you get the 05, take it apart to assess the damage and let me know what parts need to be replaced - I can then tell you what you can use from one to the other. Don't even bother with taking the 01 apart until you know what parts you need on the 05.
 

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Discussion Starter #15 (Edited)
Ok so you think I should buy the 05 instead of trying to fix the 01? Cycle shop said at least a grand to make 1 good motor out of the two and get it running. If my motor is still good can’t I just get a trans rebuild kit and the rear casing replaced?

Thank you for taking the time to research interchange!
 

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Cost of fixing the transmission and the rear case will still be about $1000 - there is no transmission rebuild kit - engine is removed, completely disassembled, damage is assessed, necessary parts are ordered (and at least two parts are not available) - if neither of the NLA parts are needed, there is still about $600 in transmission parts, rear case, bearings, seals, gaskets, rings, other misc. parts to be determined and about $600 or more in labor.

I suggest you accept your loss, buy a good running quad and try to salvage what you can of the broken quad by parting it out or selling it complete on Ebay or facebook.

What you don't yet seem to grasp is that the engine and transmission is an integrated unit - you can work on the piston, cylinder, head and things outside the crankcase without complete disassembly (however the engine has to be removed for some external repairs), but to service the crankshaft or transmission requires complete disassembly and removal of the cylinder and head is just the start of the disassembly procedure.
 

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Discussion Starter #17
Oh ok I understand now that the engine and transmission are intergraded, thank you for explaining that so well. I would like to find someone parting a 250 out with a running engine and just motor swap it, this would be less of a headache all around or buy a rebuilt one and throw it in. I’ve seen them on eBay 700-1000
 

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Unless you know the seller, I would recommend buying a running quad or rebuilding an engine/transmission that you have - some Ebay buys are shady - you might get an engine that runs fine but the clutch is out or the transmission jumps out of gear or.............

Check with powersportsnation.com (Ph: 402-371-7002) - they guarantee what they sell (and they sell on Ebay too)
 

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Discussion Starter #19
They have a fresh rebuilt one for 1199 with 100 core. Not bad for peace of mind

disregard. Out of stock
 
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