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Hello my name is pat, just picked up a 91 fourtrax300fw. It’s been rolled so it needs some cosmetic help. So my son and I already straightened the racks a bit. Next will be changing out the front left upper control arm. And we changed the oil. So my first concern is that the threads for the oil plug felt a little funny when we put it back in. Feels like they are about to strip out. I’m pretty handy with tools and am looking for the best option for the next time I pull the plug. If the threads are wiped out what are my options??? Aside from splitting the case. I here there not much material for a heli coil so I’m a little nervous as to what to do. Also what oil do you guys recommend for the from and rear diff, as well as the transfer case. Also looking for affordable tire options. Machine seems to run out great. The idle was a bit high so I turned it down and I’m hoping that will help with the hard shifting?? Also adjusted the rear brakes but how hard is it to change the rear shoes? Thanks in advance for any help and advice.
 

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welcome to the site and congrats to you and your son, on the new project you;'s have to work on together!
lots of great 300 guys here(I;however NOT one LOL)

so I am sure you can get help on any question you might have, lots of good helpful folks here!
 

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300 case is thick enough to drill out and retap oversized.

I just had to do it on my father in law's 06 Rubicon. (stolen and then recovered after a few months)

Won't work on a 420 or 500 Foreman, but will for a 300. I used this tap and drill bit set.

https://www.ebay.com/itm/m14-X-1-5-HSS-Plug-Tap-and-matching-12-50mm-HSS-Drill-Bit-in-plastic-pouch/123377073409?_trkparms=aid=111001&algo=REC.SEED&ao=1&asc=20160908105057&meid=cf5110bda10d4229ac4fbb16a2b5237a&pid=100675&rk=3&rkt=15&sd=113557696615&itm=123377073409&_trksid=p2481888.c100675.m4236&_trkparms=pageci:8c50fb5c-8625-11e9-ac0f-74dbd180aa28|parentrq:1e66370416b0ad31c3a27d30fffb2073|iid:1

then use Honda part number 92800-14000 which is a 14mm drain plug (original is 12mm) which also takes a 17mm socket. Washer for the bigger plug is 94109-14000. Will cost you less than $30 to fix it correctly. Don't overtighten it.
 

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Welcome first thing you’ll want is the manual.
Keep in mind basically three model generations. Not all components can swap interchangeably especially electrics. Carbs can be interchanged but best you stick with your year model part numbers cuz different jetting.
Always use Honda OEM parts.

Try adjusting your clutch if continues to shift hard.
Only use oil rated for wet clutch applications
 

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Discussion Starter #5
Thanks guys, picked up a new plug and tap tonight. Some Lucas engine oil. The Used A-arm showed up in the mail, now all I need is an upper ball joint, to adjust the valves (noisy) and to change out the oil on the t-case and differentials.
 
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