[ddndoug]

I just purchased a 1999 Recon with hopes to use it on some land we are buying. In the process of replacing the rear axle seals and bearings, I discovered the rear pinion bearing is shot. (I had to remove the diff to gain access to drive the exploded axle bearings out.) I'm really trying to spend as little money as possible on this almost 20 yr old bike, but I hate to not repair it properly.

I've found a 2011 and 2012 Recon diffs for sale. Does anyone know if as long as I buy the axle shaft for the newer models, will they be bolt on replacements? Thanks.

Doug

 

[wheelsquad]

when I go to cross-reference the whole diff part number, they don't match:
https://www.partzilla.com/catalog/honda/atv/1999/trx250-a-trx250-recon/rear-final-gear

https://www.partzilla.com/catalog/honda/atv/2011/trx250tm-a-recon/rear-final-gear

BUT, if you look at pinion, axle, and case set part numbers, they all match. it's hard to do much more than a comparison of that on my phone, but basically you have the input, output, and outer body as a match so if it were me, I would go for it. I did a front diff swap this past year that had less match than that and we still got it to work.

 

[ddndoug]

when I go to cross-reference the whole diff part number, they don't match:
https://www.partzilla.com/catalog/honda/atv/1999/trx250-a-trx250-recon/rear-final-gear

https://www.partzilla.com/catalog/honda/atv/2011/trx250tm-a-recon/rear-final-gear

BUT, if you look at pinion, axle, and case set part numbers, they all match. it's hard to do much more than a comparison of that on my phone, but basically you have the input, output, and outer body as a match so if it were me, I would go for it. I did a front diff swap this past year that had less match than that and we still got it to work.

Thanks, I noticed that too. I went ahead and bought a diff from ebay for same year, and ordered new axle shaft and lug.

Doug

 

[wheelsquad]

when I go to cross-reference the whole diff part number, they don't match:
https://www.partzilla.com/catalog/honda/atv/1999/trx250-a-trx250-recon/rear-final-gear

https://www.partzilla.com/catalog/honda/atv/2011/trx250tm-a-recon/rear-final-gear

BUT, if you look at pinion, axle, and case set part numbers, they all match. it's hard to do much more than a comparison of that on my phone, but basically you have the input, output, and outer body as a match so if it were me, I would go for it. I did a front diff swap this past year that had less match than that and we still got it to work.

Thanks, I noticed that too. I went ahead and bought a diff from ebay for same year, and ordered new axle shaft and lug.

Doug

Why buy a new axle though when the one your original is identical to the new ones anyway?

 

[ddndoug]

Why buy a new axle though when the one your original is identical to the new ones anyway?

Sorry, I haven't checked this in a week...

I forgot to mention one of the previous owners WELDED the right rear wheel hub to the axle shaft so it had to be cut off. For less than $100, I wasn't going to try and weld it back and hope that it was straight and true.

The good news is I got everything back together last night and took her for a test ride. After a few brake adjustments and a carb idle adjustment she was riding great. :icon_ banana::icon_ banana::icon_ banana:

I bought it from a friend who had only ridden it a dozen times or so just around their yard in about a 1 1/2 yr) after he bought it from someone else. Needless to say, it needs some maintenance! I knew going into the deal the rear bearings and seals were shot, but wasn't aware the entire rear diff was gone too. Once I got everything apart, spinning the pinion shaft resulted in a noise similar to putting rocks or marbles in a bag and shaking them. (funny thing is it never made a noise in the quad with the drive shaft being supported)

Tonight I plan on replacing the starter (it's intermittent), an engine oil change, 1st drain and refill of the rear end after repair, and hopefully adjusting the front brakes.

Doug