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Discussion Starter #1
I have a 1987 Honda 350d that having some issues. It runs intermittently. When I turn the the key on i get the correct lights and if I hear the fuel pump then it gets spark and starts right up. If I turn they ignition key i get the correct lights but don’t hear the fuel pump then it won’t start and there is no spark. If I take either wire off the ignition coil then the fuel pump will turn on. Any ideas? I have been playing around with it for the last 3 days and can’t figure it out!
 

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Has it run well for you in the past?

At this point i can only guess at CDI, unless you have an older battery.

Do you have a service manual?

Get some contact cleaner and permatex dielectric grease. Clean and lube the CDI connectors.
 

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Check the stator and pulse generator connectors (located under the seat near the airbox, right side) for corrosion. Clean and dielectric grease them before you snap them back together. Then check the fuel-cut relay connectors (inside the box with the tin cover, located near the regulator/rectifier in the right-rear wheelwell) in the same manner.

The fuel-cut relay controls the fuel pump by sensing RPMs. It does not allow the fuel pump to run unless the motor is being cranked over (or running) with the ignition and kill switch both on for safety reasons. So those connectors and wiring harness' must be in good working condition. Check the fuses and fuse box as well. If it still acts up, unplug all of the ignition switch bullet connectors and clean & grease those as well.
 

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Discussion Starter #5
I have inspected all of the electrical connections and they look perfect. I also put stabilant 22 electrical enhancer on all the connections Before I reconnected them. The battery is a year old and seems to be fine. It cranks the bike over with no problem. The fuel pump is aftermarket and I have a new one on order. I didn’t know if it could be shorting out causing the issues since it is tied into the ignition system. Thanks for any suggestions
 

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Discussion Starter #7
Sometimes it gets spark and starts up with no problem and sometimes it won’t get spark. Very finicky that’s why I’m having so much trouble with diagnosis.
 

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Start with verifying the fuel-cut relay functions 100% of the time as mentioned above. Do you have a copy of the service manual? Diag steps for the relay are covered in there. After that its all ignition diagnosis and most of that is easy if you have a multimeter. According to your explanation of symptoms there is no reason to suspect the CDI yet. Keep us posted if you can.
 

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Discussion Starter #9
I ordered new Oem fuel cut relay
The only other parts that aren’t oem on bike are ignition switch and coil and fuel pump. The ignition switch should only have 4 wires. Anybody know oem part numbers for these?
I do have a copy of service manual.
 

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You'll have to replace all of those other china parts with OEM Honda parts before you'll get it fixed. There is no sense in working on it anymore until you do. We can't help ya get china parts working cause we know from years of experience that china parts are non-functional garbage. Sorry for the rant, I just can't stress that point enough. Your bike won't ever run with those parts on there. In fact other expensive parts can/will get fried with those china parts plugged in!

Now lets get going on solving those china problems... you can look up part numbers here:

https://www.partzilla.com/catalog/honda/atv/1987/trx350d-a-fourtrax-foreman-4x4

But first make darn sure that your bike is a 1987 TRX350D and not a TRX350. The year and model must be correct because the 87 350D is a one-of-kind machine. Ignition & electrical parts from other years and models do not interchange with the 87 350D.

The coil for an 87 350D is #5 on the parts fiche:

https://www.partzilla.com/catalog/honda/atv/1987/trx350d-a-fourtrax-foreman-4x4/wire-harness

Fuel pump is #5 here:

https://www.partzilla.com/catalog/honda/atv/1987/trx350d-a-fourtrax-foreman-4x4/fuel-tank

The ignition switch is #4 here:

https://www.partzilla.com/catalog/honda/atv/1987/trx350d-a-fourtrax-foreman-4x4/handlebar

That Ign switch is discontinued so you'll have to scrounge for either an NOS Honda switch or a used one. Remember, aftermarket do not work, OEM Honda only. AND the OEM switch that you buy MUST match the part number exactly. Other year/model switches do not fit that bike. And most folks don't know that.

Right now you are at a very high risk for frying other components (CDI is next likely candidate to burn if it hasn't already!) on the bike due to those china parts being on there. Disconnect the battery cables immediately and don't connect them back up until every china part has been replaced with OEM parts having the correct part numbers for your year/model.

If there are any wiring harness cobbles or splices then thats suspect too. So look those harnesses over carefully. Replace if someone has "worked" on any of them.

Keep us posted... I imagine the only thing wrong with your bike is someone put china parts on it.
 

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Discussion Starter #11
Guy at local Honda dealership said ignition switch part number 53100-ha7-675 would work. It has six wires on it though and mine needs only 4.
 

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Guy at local Honda dealership said ignition switch part number 53100-ha7-675 would work. It has six wires on it though and mine needs only 4.
No these are available let me look around
Check my parts links below and then check fleabay i just bought nos for mine.

Gotta make sure you only buy OEM parts.

Key switch right? Yours has to have more than four leads? Oh well looking at schematic maybe only 4
Here’s one power sports nation THIS advert incorrect
 

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Dead wrong. First of all that part number does not exist. The only number close to that one is 35100-HA7-675, which fits the 86 and 87 TRX350A. The TRX350A models have AC-CDI ignition systems. The 87 350D has a DC-CDI ignition system. If you plug that switch in your CDI will go up in smoke. Run away, don't walk, RUN from that dealer. Whoever told you that is an idiot that cannot be trusted with your money.
 

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Ahhh wait a minute

Sorry
The 87 88 Foreman has 4 leads and the 86 87 fourtrax has 6

Here’s a four wire switch for a Foreman but from an 88– @retro do you think that’ll work
 

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Discussion Starter #15
So I have found everything except for the key switch part #35010-HA7-751. Is there any way to get around using this one since it isn’t available?
 

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@Goober @Rstiles11

Yep, according to the wiring diagram the Ign switch pinouts and wiring connectors are the same on all 350D models. So a switch from an 88-89 350D should work fine on an 87 350D if those wires are long enough to plug into the main harness. I don't see any reason why they wouldn't be.... I'd go for it!
 

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Sounds promising
Here’s the two I found on fleabay
Ive purchased from the Provo shop successfully and it’s cheaper anyway both offer free shipping
 

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