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Discussion Starter #1
Hi, this is my second post here, first one over in the intro section...

I’m working on getting my late dad’s fourtrax running. It sat for 12 years. I’ve rebuilt the factory carb. Soaked the carb body, blew out all the passages, installed new jets, replaced the choke cable, new air filter, plugs, and all new fluids (Honda spec’d), drained fuel, new fuel lines filter, battery. I think that’s about it.

Sometimes the quad will start and run absolutely fine. I can drive it around, take it for high speed runs, putt around the yard, let it idle forever. Then some times it starts fine, idles a little goofy, and the bogs down with an insane hesitation if I give it gas.

I have no idea where to go from here. I’ve torn the carb down multiple times and recleaned it, verified the slide diaphragm has no holes in it, but cannot get it to consistently run. Any help is appreciated. This bike means so much to me because of the great memories I have of it with my pop. Thanks in advance!
 

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Update: I’m pretty sure my issue could be related to the choke. I replaced the cable and I’m wondering if I got the wrong one and maybe that could be causing my issue? When I choke the bike after warm up it sputters and it dies immediately. It does not idle up like I thought it should. Thoughts?
 

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Did you replace the starter valve? It’s what the choke cable hooks to—that oring has to be pliable and conically shaped—pointing into the carb

If it’s rounded or brittle it’s done. New valve kit costs ~ $40

Also make sure your vacuum piston seal is seated well and no perforations
 

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Vacuum piston is good. I even checked it with a super bright light for pin holes. I did order a new choke valve as I’m still using the old one. It ran great today, but it seems to be intermittent between barely able to idle and then runs like a top. Thanks for the advice- I’ll definitely be changing the choke.
 

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What model and year do you have , you mention the fuel enrichment valve ( choke ) might be the wrong one -----if you are dealing with a 300 , then there are two different length plungers from 1st to 2nnd generations ------ another thought did you clean the tank out , maybe pieces of trash/water are making it's way into the carb , or the screen in the tank or the petcock is blocking up and restricting flow
 

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OH , I see now the model and year was in the heading , which I couldn't see with your post , 88 is the short plunger
 

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I’ve been traveling for work, but here is my update:
Ordered new choke just to be sure, replaced that and rebuilt the carb again. Verified I have good spark, but ordered a new CDI/coil as well.

Put everything back together and she started and idled great, throttle worked as it should, etc. let her warm up so I could do fine tuning and she started to idle a little erratically, then when I went to tap the throttle it died. Started her back up and she idles with a very slow hesitation and as soon as you try to give her throttle she gets even worse. I have a video of it but haven’t figured out how to post that yet.
 

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Do you have the manual?
Sounds like fuel flow problems—is tank clean?
Do the fuel flow test on the ON and RESERVE settings
If flow is slow then petcock could be clogged
 

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Discussion Starter #9
I do have a factory service manual. I’ve tried with Petcock on reserve and on with no difference. Fuel flowing fine into carb and I have an in-line filter. Tank looks clean inside but I’ll try cleaning the petcock as well.
 

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Hi, this is my second post here, first one over in the intro section...

I’m working on getting my late dad’s fourtrax running. It sat for 12 years. I’ve rebuilt the factory carb. Soaked the carb body, blew out all the passages, installed new jets, replaced the choke cable, new air filter, plugs, and all new fluids (Honda spec’d), drained fuel, new fuel lines filter, battery. I think that’s about it.

Sometimes the quad will start and run absolutely fine. I can drive it around, take it for high speed runs, putt around the yard, let it idle forever. Then some times it starts fine, idles a little goofy, and the bogs down with an insane hesitation if I give it gas.

I have no idea where to go from here. I’ve torn the carb down multiple times and recleaned it, verified the slide diaphragm has no holes in it, but cannot get it to consistently run. Any help is appreciated. This bike means so much to me because of the great memories I have of it with my pop. Thanks in advance!
 

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I do have a factory service manual. I’ve tried with Petcock on reserve and on with no difference. Fuel flowing fine into carb and I have an in-line filter. Tank looks clean inside but I’ll try cleaning the petcock as well.
Well maybe it’s an ignition thing—i think there’s a diagnostics table you can use on page 20-4.
double check the overheat system Ohms check the oil temp sensor and see if it’s in spec.
Possible the CDI is giving you problems. Try this it won’t hurt anything. Dry out the CDI like you were making some oven jerky. Put in an oven (connector side up) and turn the oven on no higher than 200F. Let it dry out for at least three hours. Let the CDI cool down completely before you reinstall it.
Here’s a pic of my 93 carb VE90E this is after disassembly and before cleaning. See anything familiar? Remember to check the teeny port where the pilot jet screw (circled) comes up through the carb bore—make sure it’s clear and you can barely see the tip of the pilot jet screw. Make sure you’ve synchronized the carb/throttle cable.
149210
 

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Discussion Starter #12
Thought I’d give a final update and thanks to those who helped. It ended up being the CDI. I got so frustrated, I took it to a dealer, who was certain it was the stator. I put a new stator/pick up coil in it and had the same problem. Snagged an OEM CDI box from HoT and boom, she runs like new! Thrilled to have this machine up and running again. Will rehab the plastics and repaint the frame/racks this summer. Also, scored a 85 TRX 250 utility the other week that was Stuck in reverse for $80. Pulled left side case and it needs a new shift drum center. Parts ordered. Hoping to post a few pics of my machines when I get a chance. Thanks again all!
 
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