I bought my son a 2004 2x4 bayou 250 for trail riding knowing it was a project bike. We got started on the work repaired the rear end and started diagnosing the engine trouble. I was hoping to find a minor valve issue and later found little oil in the crank case and a stick point when pulling the starter cord with spark plug removed. I would like to send it to a machine shop at this point to access and possible rebuild as it is beyond my capability. The engine is removed and none of my local backyard mechanics have the time. I want it to be done right for him as he will be trail riding but I hope I didn't get into a major expense. Does any Know of a good machine shop or mechanic we live in RI but I could crate it up.

Thank You

 

I have a feeling it would cost a lot just in shipping to get your engine shipped out to a mechanic and back to you.

It sounds like you are at least a little mechanically inclined. Maybe you and your son should tackle it yourselves as a father/son project? Honestly, doing a top end on one of these engines is a simple job with a torque wrench, feeler gauges, and some time. There are also lots of great folks here that will help you if you get in a jam. Most of the time the bottom end on these engines are good, they just need a top end rebuild. If you pull the top end off you can inspect the rod and if it seems good, then take the jug and old piston to the machine shop to have it measured to see what overbore you need. Then go buy your piston and take it to the machine shop and let them bore and hone the jug. You will probably only need the first oversize unless it is scored pretty badly. Then put everything back together with new gaskets and seals and torque to specs. It really is simpler than you think most likely. Some people dont have the place or tools to work on it and if you dont, that is fine, but if you do, it may be worth a shot.