Bought a 2012 Recon TRXTM 250. Not in very good condition so I tore it down to check everything. Did not get into the gears but did a top end, new clutch pack and centrifugal, new cam ( dropped the old one and it broke in half).Fired it up and it runs perfectly. Until I put it in gear. It lurches forward and stalls immediately. When I replaced the centrifugal clutch, the one way clutch bearing seemed a little worn but I could still spin it counterclockwise after cleaning and oiling. Of course that was holding it in my hand. Someone mentioned to put the machine in first gear ( with engine off) and roll it backwards. If it does not roll freely, the one way clutch is locking up. My idle RPM's are low and carb is new. Don't know what else to check.

 

"put the machine in first gear ( with engine off) and roll it backwards. If it does not roll freely, the one way clutch is locking up"

Well, did you, and does it? If it does lock up, try rolling it forwards, if it doesn't lock up that way, then you have put the one way clutch in backwards, not sure you can on a Honda 250 but a common mistake on many ATVs. Anyway, you do have a clutch fault, so take the cover off and inspect it. Not easy to see until you remove that centrifugal oil filter, but a shoe spring may have broken or not been fitted right.

 

WwwwwIt rolled about two feet and stopped. Rolled it forward a couple inches then backwards again. Went a little farther this time but stopped again. Should have changed the one way when I pulled the clutch. It worked ok when I spun it while holding it but failed under real conditions.

 

That is the test for a slipping clutch, or one that is the wrong way round, your problem is it seizing. It should not show any resistance being rolled backwards in 1st, but should lock up if you roll it forwards, as it's job is to ensure the drive doesn't disconnect on the overrun, if the centrifugal slows enough to drop out.

 

Got it. The one way seemed to be hit or miss. It would be ok at times then fail. I’d never experienced that before so I thought it was something else. Took a leap of faith and just changed it. I Did the first gear backwards roll and it rolled without a problem. I’m so relieved! Kinda expensive but that was the issue. I’ve been jacking with that crankcase cover so many times I’ve got a couple bolts that won’t tighten up. Bolts look ok so I guess I stripped the holes in the crankcase itself. Just another fun day in the shop! Thanks for all your help.