Hi everyone, I recently purchased a Honda TRX300 FW Fourtrax quad in need of some repair. However, after some stripping back of the plastics and wheels, I found it needs a lot of work to get it right, so I have decided to do a full overhaul on the quad. I will post progressive photos from the beginning and will be asking for help along the way! Feel free to comment and give advice when needed as I don't admit to knowing it all!
My dad ( Bluezulu49) will also be in on the project and we hope to have the bike running again by the end of July/early August.
So far, we have done the following:
We have removed:
All racks front and back and the plastic mudguards.
The fuel tank (has a bad dent on the left side, any suggestions as to how to pull it out would be appreciated).
The whole front end of the bike, all brake components, hubs, knuckles, bearings, swing arms and a lot of the electronics.
The steering rack.
The cooling fan (motor is seized but we managed to buy a brand new old stock fan).
The exhaust pipe.
Along with my father, construction wise, we have so far:
Cleaned the 4x swing arms and repainted 3 of them.
Cleaned the stainless steel shrouds that sit at the back between the brake shoes and the knuckles on the front end.
Cut off the rotten steel from the bash bar and replaced with new steel, like for like. (I'm a carpenter by trade but have picked up the knack for welding over the years!).
I have spent a considerable amount of money on new parts which include the following:
New exhaust pipe and gasket.
New brake shoes and springs, front and back.
New knuckles x2.
Second hand brake drums.
Bearings for the front hubs.
New steering rack components.
New rear axle.
New brake fluid pipes x2 (they bolt onto the back of the brake guard on the front end).
New cooling fan motor.
New brake cylinders.
I may have missed a few things but there are more items still to be ordered, i just need to see what else needs replacing/ repairing first.
The next job is to remove the front driveshaft and engine to inspect the bottom side of the chassis.
Any pointers and tips are welcome, I will post up some pics shortly to show you what we have found so far.
Hope you enjoy the thread!