Blue 300 4x4 Project - Page 84 - Honda ATV Forum
Honda FourTrax Discussions for the FourTrax Rincon, Foreman, Rancher, Recon

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post #831 of 875 (permalink) Old 05-20-2019, 06:41 PM Thread Starter
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Got some time on the blue 300 , went to put the side cover back on and one of the bolt holes was broken at the case , cut a bolt and JBWeld'ed it in like a stud , tried a dry fit and I think it is going to work ----I'm in striking distance to ride this one again soon
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post #832 of 875 (permalink) Old 05-23-2019, 04:17 AM Thread Starter
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Things went > not good ---- after getting the engine back together , I don't have the neutral light , the reverse light and the temp light is not lighting up for the few seconds it usually does when the key turned on , the only thing different is I installed the sub-harness I got from Jeep ( thanks Jeep ) , it looked the exact same , part interchange says they are all the same 88-2000 , so I doubt that is a problem ------ so it won't spin from the button , I have the green wire grounded to the block and even tried a jumper wire direct to the battery negative to the green wire , also the spark is there but weak , can barely see it and it is not constant , I did manage to shock myself and it won't pop on ether ------

second problem , which is solved now but wasted a lot of time figuring it out , I jumped the solenoid to try and see if I could get it running without the light lit , it sounded very funny , like the valves were out of adjustment , phit , phit , phit , so after several times of checking the timing mark , piston top dead and readjusting the valves which were all ok , I was scratching my head , the exhaust was still disconnected and while I had my hand in front of the exhaust port while spinning , nothing was coming out , found a mud diver built a huge nest in the exhaust port and had it so blocked up that the compression of the engine wouldn't even blow it out ----used a vacuum cleaner , a screw driver and a small wire brush to clear the port

so right now , none of the dash lights light up and the spark is weak and not 100% , brand new plug
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post #833 of 875 (permalink) Old 05-23-2019, 07:45 AM
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I hate wiring issues. That harness was off of a parts bike so you might check and make sure the wires are good (test light or multimeter to make sure there isn's a break inside the insulation somewhere). If you're grounding the green wire sounds like you have another issue.
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post #834 of 875 (permalink) Old 05-23-2019, 10:34 AM Thread Starter
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Quote:
Originally Posted by Jeepwm69 View Post
If you're grounding the green wire sounds like you have another issue.
I spent some time on it today

The problem is no ground to the dash light sockets


I have power to the neutral and reverse light sockets when it is in neutral or reverse , so that eliminates a bunch of things , I tested the both light bulbs and they work ------------ the problem is I don't have a ground on either light socket , didn't try the temp light yet but would presume it is the same thing ,no ground --- I guess I need to get the book and see where the ground is coming from , my buddy told me he seen the same thing and it was the diode , I swopped the diode this morning and no difference , but didn't test either diode yet

I just pulled the front rack and fender to access the wiring
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post #835 of 875 (permalink) Old 05-23-2019, 04:55 PM Thread Starter
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I figured out the ground problem for the neutral light and to start by the button , and the spark is solid now , the reverse light still doesn't work and the temp light doesn't light when the key is turned on , the problem was a bushing /insert /or part of the male plug was inside the replacement sub-harness and the plug wasn't going all the way in ---- found a hole in my muffler , not going any where , anytime soon , going to most likely go with a slip on type muffler
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post #836 of 875 (permalink) Old 05-24-2019, 04:47 AM Thread Starter
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The hole in the exhaust is a bummer , the muffler had an exhaust snorkel on it , thought about welding the hole , but after taking an awl and picking around , there are other spots rusted and the after market muffler is thin to start with , it needs a new muffler and the 92 is going to be a little hard to find ---I actually have a 88 on it right now , so I know 88-92 will work ----- Manny would you have a 1st gen muffler
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post #837 of 875 (permalink) Old 05-24-2019, 06:46 AM
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Tagging @Manny for @fishfiles
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'95 TRX300FW
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post #838 of 875 (permalink) Old 05-24-2019, 08:37 AM
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Quote:
Originally Posted by fishfiles View Post
The hole in the exhaust is a bummer , the muffler had an exhaust snorkel on it , thought about welding the hole , but after taking an awl and picking around , there are other spots rusted and the after market muffler is thin to start with , it needs a new muffler and the 92 is going to be a little hard to find ---I actually have a 88 on it right now , so I know 88-92 will work ----- Manny would you have a 1st gen muffler
Wrap the sides of the muffler with sheet metal and hold it in place with hose clamps.
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post #839 of 875 (permalink) Old 05-25-2019, 04:12 AM Thread Starter
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[QUOTE=Jeepwm69;

Wrap the sides of the muffler with sheet metal and hold it in place with hose clamps.[/QUOTE]

That is a great idea for a land bike , my muffler is under water a lot , in fact this is the only bike I have that has a exhaust snorkel on it , so it needs to be water tight as a gooses' butt ---maybe I could use some putty and a coffee can cutting with some hose clamps like you mentioned and make it water tight for this hole , it has a couple of other rust spots that I don't think are thru yet , but if I were to pick the scab I bet it would bleed exhaust , LOL
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post #840 of 875 (permalink) Old 05-25-2019, 08:41 AM Thread Starter
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SamUK is sending me a 1st gen Rick's CDI from across the pond , old blue is going to be international , I think that the cdi might be the why the temp light quit working

Started the winch mount , paper work says 90-92 , but it doesn't really fit , looks like I could take off the rack supports , drill thru the winch plate and put the rack support tube on top the winch plate , it would be a 1/4 inch higher , but I should be able to make it work
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