a1ckunze

Hey everybody. I'm new to this forum thing, but I've been been directed here from a trusted friend. I just recently purchased a 2002 Honda 250 ES Recon it will pull start and run just fine but when I try and use the electric starter I get this horrible grinding sound. I have pulled the starter out and it works fine so after I have done a little reading I think I'm down to the flywheel and starter clutch needing to be replaced. I think I'm capable of replacing these parts myself be could really use some step by step guidance or perhaps a shop manual. I'm trying to save some money by doing it my self and I'm afraid to spend money on the expensive manuals. Any guidance will be greatly appreciated. Thanks

Helmut

Yeah, it's pretty easy to change the starter clutch. You will need a flywheel puller. Make sure you put loctite on the bolts that hold it to the back of the flywheel. Click on the link below to to download the service manual. After you click on the link, click on "Click here to start download from Mediafire..".

1997-2004 Recon 250 Service Manual

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2000 Foreman 400
2004 Grizzly 660
Both stock, except for Mudlites and Kimpex rear storage box.

rich450es

welcome to the forum man!

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a1ckunze

Hey again. I got my manual downloaded and its exactly what I needed thanks so much for that. I took my recon out this weekend to help a neighbor do a controlled burn on some of his property. I'm just now realizing how useful these atv's can be. Any way I had said that I needed to replace my starter clutch and flywheel, well I was running along in third gear needed to down shift into second, when I did there was an unusual buzzing noise before it went into second, then when I tried to go to first the ES stuck between 1st and 2nd. I got the manual shift tool out and managed to get the transmission back in to neutral and the ES too. For some reason after I did this I thought I would try the electric start just cause and it WORKED!! It is still working but there is some pretty nasty banging and clanging sounds while the starter is engaged for a few seconds. There is no doubt that it is probably going to malfunction some time in the near future but my question is am I doing irreversible damage to other parts of my machine or will it be alright to continue using it until it finally quits for good? Again any insight or info is really helpful and appreciated. Thanks

a1ckunze

I'm getting ready to order my starter clutch and flywheel but cant find any that are for and 02 Recon ES, but I've found some for an 04 ES, I think I understand that any from 02-07 should work but would like some reassurance.

Helmut

You don't need to change the flywheel. Sometimes, you can get by with just changing the one-way starter clutch, but if it's wore bad, you may have to change the big starter gear that fits into the back of the one way starter clutch.

ADDED: Just realized that you were probably talking about the big starter gear when you said "flywheel".

I would have thought those parts were the same exact thing between those years, but I looked up the part numbers and the one-way starter clutch has a different part number. That doesn't mean it won't fit though. It could just be an updated part. The part numbers for the starter gear are the same.

__________________
2000 Foreman 400
2004 Grizzly 660
Both stock, except for Mudlites and Kimpex rear storage box.

a1ckunze

Hey again, well I got my recon all tore down and was going through the manual and checking parts and realized who ever had worked on it before me had forgot the 6 screws that hold the starter clutch to the starter gear. I now have it all put together and running good now. Thanks for all the help, advice, and input. Without it and the manual link I could not have had such a smooth and quick repair job. Again thanks to all