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Discussion Starter · #1 ·
Got the racks and all the plastic off. Was surprised to see no hidden damage on the plastic. Just dirty of course. Started working on getting the top half off and that is where the crap started. I used WD40 and liquid wrench on a couple of bolts and finally got them broke down and out. All except one. This bad boy just doesnt want to leave his home. I threw an 8mm wrench on it and the stupid bolt head started stripping. Its almost like the 8mm is a hair to big. Do they make a 7.5mm?
 

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They're 8mm, I would use a 6 point socket or 6 point wrench.
 

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Discussion Starter · #3 ·
Yeah, I was just being a smart aleck. Seriously, I starting to get a little frustrated. So far Ive worked on this thing a total of about six hours and all Ive got to show for it is all the plastic is off and I got the carb off. Oh, got the exhaust off too. But Ive had to grind off 3 bolts and drill out one screw. Today I just soaked the crap out of some bolts with Liquid Wrench and that really helped a lot. Tomorrow I hope to have that top half off!
 

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Discussion Starter · #4 ·
I started on pulling the cam today. Clymers kept telling me to unbolt both screws from the flywheel where the chain attaches. I only had one bolt. I didnt think too much of it. Until I pulled the cam out. It had a top bolt, but the bottom half had no bolt, oh, and where it was supposed to be was just a broke off bunch of mess. So that bolt and some more crap are obviously down inside this thing. What you guys think? Should I be freaking out about this crap down in the bottom?
 

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I would probably pull the right side cover off and try to find it, just in case.
 

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if your missing a cam bolt..then it's down inside the right side like helmut said..you need to pull the right side cover off..may not hurt to get a gasket for it ( just in case your luck is like mine..and it always tears..lol )..this would be a good time to remove the oil pick up screen and clean it ..inspect your clutch disk and clutch arms...if you don't want to drain your oil... ( as if you just put new oil in it )..turn the bike up on it's side..about a 45 degree angle..support it with a floor jack..or jack stands..this will let all the oil go to the left side..and you still can take the right side off..without draining your new oil...try to find a magnet..one of those that retracts..and stick it inside the motor's lower end..where ever there is a hole..and see if you can find that bolt head that broke off..it would probally be easier if you just drain the oil..and take the side cover off..and search for the bolt head with the magnet that way..so it wont roll over to the left side...if you already have drained the oil..and the top end is still off..you can feal around inside where the piston goes down..and if that bolt head is in there..you should be able to pick it up with that magnet..i just did this for a trx300 the other day..the piston broke off the lower end of the cylinder..and i had to remove dang near all of the side covers..and use a magent to find the broken parts that was still inside the lower half of the engine..lol..be thankful you just got one thing to find..lol.
 

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Discussion Starter · #7 ·
I kept the engine on the frame to take off the top end. I dont think that is going to happen. It seems I dont have enough clearance to get this thing off. Please tell me Im doing something wrong and that I can take it off without removing the whole motor.
 

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I kept the engine on the frame to take off the top end. I dont think that is going to happen. It seems I dont have enough clearance to get this thing off. Please tell me Im doing something wrong and that I can take it off without removing the whole motor.
It's been years and years since I worked on a Fourtrax 250, but I believe it will come off with the engine in the frame. You're not trying to pull the head and cylinder, both, off together, are you?
 

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It will probably be a tight fit coming off, but it should come off. Like I said, it's been years since I've worked on a Fourtrax 250, but I can't remember having to take the engine out of the frame to pull the top end.
 

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Just thought of something. If you have a factory service manual for the Fourtrax 250, it should tell you if the cylinder will come off with the engine in the frame. It should tell you in the very beginning of the chapter on "cylinder/piston". The beginning of each chapter should tell you what can and what can't be removed with the engine in the frame.
 

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Word:gotmyvote: Basically, Chill and Use your head. When you break um down in your mind, you can see just how simple these lil motors really are. You know how, and you know you can see-it-through to completion. Your doing fine ole buddy. I'm a real stickler for details also. Which in turn, I sometimes read too much into things. Kinda like this entire posting, for instance. Anyways..... Life's a garden, Dig it. And to each, His own. God Bless :icon_cool:
 

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you do not need to pull the motor just to take the top end off..the rocker box, the head. and the cylinder will remove with the motor still in the frame..just make sure you remove the engine mounts on the top part of the engine..then the rest will come off..if i remember right..there is two long bolts on the rocker box that are really close to the frame as you pull them out..soo..it's a tight fit..until you remove these two long bolts..you can't get the rocker box off..once this is done..remove the head..then remove the cylinder..good luck.
 

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Discussion Starter · #14 ·
Thanks Jam for the chill out nudge. I told myself that there aint no way Im getting this thing done before Labor Day. So I figured out that this moron was indeed trying to take the head and cylinder off at the same time (idiot). So today I got them both off along with the piston. As bad as it was smoking I really expected to see a big ole hole burned through the piston, but it didnt look that bad. Just some carbon build up. Once I got all that squared away I decided to get that right side off so I could that cam crap outta there. This is when a really nasty cotter pin introduced himself. I had to move some crap around to get to all the bolts. Well, I knew that cotter pins arent rare but are cheap so I introduced him to my Dremel and didnt have an issue after that.

I'd like to keep posting my progress on here, if its cool with you guys. If not just tell me to STFup. lol
 

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I'd like to keep posting my progress on here, if its cool with you guys. If not just tell me to STFup. lol
Post away. It might help others.
 

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Thanks Jam for the chill out nudge. I told myself that there aint no way Im getting this thing done before Labor Day. So I figured out that this moron was indeed trying to take the head and cylinder off at the same time (idiot). So today I got them both off along with the piston. As bad as it was smoking I really expected to see a big ole hole burned through the piston, but it didnt look that bad. Just some carbon build up. Once I got all that squared away I decided to get that right side off so I could that cam crap outta there. This is when a really nasty cotter pin introduced himself. I had to move some crap around to get to all the bolts. Well, I knew that cotter pins arent rare but are cheap so I introduced him to my Dremel and didnt have an issue after that.

I'd like to keep posting my progress on here, if its cool with you guys. If not just tell me to STFup. lol
yep..post away..as i stated in my post..if you learn something..pass it on to the next..someone else may be in your shoes some day !..but..glad your doing well..thats the best part of working on it yourself..you save money..and you learn how to work on your ride..keep it up !
 

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Discussion Starter · #17 ·
Got the right side crank cover case off. Fished around in there with the magnet and found absolutely nothing. No bolt, no junk, no nothing. So Im assuming that the previous owner had gone down in there and got all the crap outta there. So a big sigh there. Going to get the cylinder shipped off first thing in the morning for a little light running machining. Got a carb kit coming already. Did some painting on the utility racks this afternoon. Hey, is there anything I can do to the exhaust/slash muffler to give it a little more bling? Its a total rust bucket right now and I was going to hit it with some 3-in-1 oil and a little sand paper. Anything other than that?

Lessons learned so far - Use the right tool. If you don't have it - get it. Funny how easy it was to get off stubborn bolts with a 42 foot long breaker bar. #2 - If it doesn't come off easy, then you missed a bolt somewhere #3 - Relax - this stuff is fun so stop friggin stressing!!
 

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Got the right side crank cover case off. Fished around in there with the magnet and found absolutely nothing. No bolt, no junk, no nothing. So Im assuming that the previous owner had gone down in there and got all the crap outta there. So a big sigh there. Going to get the cylinder shipped off first thing in the morning for a little light running machining. Got a carb kit coming already. Did some painting on the utility racks this afternoon. Hey, is there anything I can do to the exhaust/slash muffler to give it a little more bling? Its a total rust bucket right now and I was going to hit it with some 3-in-1 oil and a little sand paper. Anything other than that?

Lessons learned so far - Use the right tool. If you don't have it - get it. Funny how easy it was to get off stubborn bolts with a 42 foot long breaker bar. #2 - If it doesn't come off easy, then you missed a bolt somewhere #3 - Relax - this stuff is fun so stop friggin stressing!!
lmfao..yeah..i'd say your learning alot !..lmfaooooo.
 
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