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Repair & Maintenance Having problems? Doing a rebuild? All Repair/Maintenance Discussions here.

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post #141 of 201 (permalink) Old 03-29-2019, 10:14 PM
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I replied to your other thread Tony that diagram might be illustrating the oring. I don’t know why. Honda does not sell the conical oring separately or in a kit—that i know. You have to buy the starter valve kit.
There are only four orings in the rebuild kit that you will use:
The large gasket with the integrated small gasket us used on the bowl.
The pilot needle uses the small and tiny oring
The drain screw uses the small oring.
If i missed one someone will correct me
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Last edited by Goober; 03-29-2019 at 10:18 PM.
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post #142 of 201 (permalink) Old 03-30-2019, 03:17 PM Thread Starter
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Okay, thank you goober
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post #143 of 201 (permalink) Old 04-11-2019, 08:42 PM Thread Starter
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Keep in mind that the quads are old—every time you inspect something there’s a chance you’ll break it. LOL it happens[/QUOTE]

Okay @Goober you called it. . I finally got all the parts together and got the carb, choke cable, starter valve and primer bulb installed and I find that the original Choke lever is sloppy and won't hold the cable in place . So now I'm going to order a new lever.
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post #144 of 201 (permalink) Old 04-12-2019, 03:22 AM
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Keep in mind that the quads are old—every time you inspect something there’s a chance you’ll break it. LOL it happens
Okay @Goober you called it. . I finally got all the parts together and got the carb, choke cable, starter valve and primer bulb installed and I find that the original Choke lever is sloppy and won't hold the cable in place . So now I'm going to order a new lever.[/QUOTE]

chances are, there is nothing wrong with the choke lever ?. most levers never wear out ?, what does wear out ?..is the switch housing ?, or the lever spring that rides in the back side of the lever. you can take the switch housing apart to get to the spring, the lever is held in there by a tiny pin with a tiny c-clip, pesky little bugger if your not good with your hands ?..lol. the hard part is getting the front button off the lever !!, its tricky as all get out to get off the lever without damaging either one ?!. been there soooo many times..lol.

'89 trx350D foreman 4x4...'85 vf700c magna, '03 trx450fm foreman 4x4 , 2015 Yamaha waverunner fx cruiser ho, '08 vt750c2 shadow spirit
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post #145 of 201 (permalink) Old 04-12-2019, 04:08 PM Thread Starter
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This all happened after I put the new OEM choke cable and new starter valve on last night. I had it in the lever but was having a hard time attaching the starter valve while trying to depress the spring, seemed i didn't have enough cable. So I disconnected it from the lever and got the other end all put together and screwed it into the carb, well then I was having a difficult time reattaching it to the lever and I heard a pop or snap around the lever.
So is there a correct way to get that all put back together without the "pop/snap", if so PLEASE elaborate.

Thanks, Tony
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post #146 of 201 (permalink) Old 04-12-2019, 04:40 PM
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you most likely got the years mixed up , the cable , the head light assembly ( which incorporates the choke lever ) and the fuel enrichment plunger ( choke ) are all a set for the first and second gen bikes , so you can't put a second gen cable on a 1st gen bike and so forth ---then to make matters more confusing , I don't think you can get the short plunger ( 1st gen ) any more , they sell you a plunger kit with a longer plunger and a tube that adaptors to the 1st gen bike cable length


it could be as simple as you are not getting the cabe end into the plunger , do you have the other end of the cable disconnected when you were trying
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post #147 of 201 (permalink) Old 04-13-2019, 02:42 AM
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you most likely got the years mixed up , the cable , the head light assembly ( which incorporates the choke lever ) and the fuel enrichment plunger ( choke ) are all a set for the first and second gen bikes , so you can't put a second gen cable on a 1st gen bike and so forth ---then to make matters more confusing , I don't think you can get the short plunger ( 1st gen ) any more , they sell you a plunger kit with a longer plunger and a tube that adaptors to the 1st gen bike cable length


it could be as simple as you are not getting the cabe end into the plunger , do you have the other end of the cable disconnected when you were trying
I dont know how long the enrichment valve is on the kit I purchased from partzilla just the other day ?, it was for this '88 trx300fw project I am working on. I bought the cable, and the choke all in a kit. as you and I both know, those parts fich don't show a close up good picture of anything !..lol. i'll post an update either in this thread or my build thread on my findings once I get that order in :-).

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post #148 of 201 (permalink) Old 04-13-2019, 05:14 AM
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Shade , I think you will be getting a long plunger , the difference of the cable lengths will be taken up with the tube that come with it , let me know how that works out for you
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post #149 of 201 (permalink) Old 04-15-2019, 07:56 AM Thread Starter
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So this is what I ordered from Partzilla
1991 TRX300 A - FOURTRAX 300
VALVE SET, STARTER #16046-HC4-840
CABLE, CHOKE #17950-HC4-671
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post #150 of 201 (permalink) Old 04-15-2019, 03:37 PM Thread Starter
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