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Discussion Starter · #1 ·
Hi everyone!

I recently inherited a 1998 Fourtrax 300 4WD. I was quite exited to get it fixed up and going. You can see pics in my introduction post. I hoped to just have to do some minor repairs, clean the carb, and replace all the fluids. This is all I know how to do anyway.

Unfortunately, it appears that the last time the bike was used (a few years ago) it had been swamped. I'm not sure what to do next. Some pictures below. Any suggestions?

Airbox:


Tube leading into airbox:


Carb:


Oil filter:


Water in oil:
 

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Judging from looking at the pics of the oil filter , the water in the oil , the sand in the air inlet and the two years of time ( I believe you said 2 years ) that went by since this all happened , I think you only have one option , to split the case and inspect and then make a determination if is is feasible to rebuild the engine or look for another one , any thing is rebuildable with enough money , but it comes to a point of whether or not it is worth it

you could flush it with diesel several times , fill it up with fresh oil , test the compression , and see if you can get it to start , but if there is sludge in the case , it is not going to last long

you may want to keep this one as a part bike and find another same gen 300 to build
 

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I’d be splitting the cases on this one.


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what a quick flush won't get her back up and running in NO time here?? LOL
come on some of the new HIGH TEC oils we have today should be fine here, I see many say they have added cleaning agents in them? HAHA!

NO I agree with Fish here, open this thing up and see, Many things might be rusted to all heck and be worthless to re use and rebuild
I'd also be looking at axles too, as odds are they will have issue's too , if diffs have as much water in them as motor had!
 

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You have a lot of options and it looks like you still have enthusiasm to work on it. There are two paths for you:

Short cycle time you can sell or part it out to someone who has the ability to bring it back. Down side is you will always want to have gotten your hands dirty. Up side you learn enough about these machines to buy one that runs for $2500 and work on that one—use yours as a Parts machine.

Long term you could rebuild and restore it. This might take you at least a year and maybe three. Find another with a bent frame. Send the engine off to a rebuilder or buy an engine off a parts machine. Rebuild the carb, axles, side gear, swing arms, everything with grit/dirt in it. Hunt Parts houses, fleabay and kreigzleist and be at least $3000 invested.
 

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Discussion Starter · #6 ·
This all makes me sad. Im happy to get my hands dirty and learn, but spending a year rebuilding it...

How much work is splitting the case? If I did that and posted some pics would you folks be able to help me determine if it needs rebuilding? I guess I am holding on to some hope I can get this guy living again without an engine rebuild.

Thanks so much for all of your great insight so far!
 

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You could probably find another complete engine for under $500, so there is that option if you feel like splitting this one is maybe too much work or beyond your capabilities.


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It sounds to me like you might be a lot more capable than many other rookies... :) You got the bike free and are itchin' to get dirty, so why not tear it down and find out whatcha got? You got nothing to lose here... but you'd gain a lot of knowledge and learn some new skills and work habits that you can and will apply elsewhere as you age... If its beyond repair so what! If its repairable cheap then you are a courageous winner! Your only other option at this point is to turn your back on it, throw your wallet at it, and hope you get lucky with a used motor. Lets go boys... :)
 

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Ok guys go ahead and trash me.... I'm waiting for it..........


If $$ & time is an object, I'd flush the motor out with a lot of diesel fuel. Be sure to do it mulitiple times. I mean FLUSH. It's always worked for me with out having a smoking motor after the fact.

With that being said, the "right" way to do it is split the cases. I've never done so yet. I've always opted for Diesel and lots of it!
 

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The nice thing about splitting the case you get a chance to look at every including and not limited to bearings, etc. If you take the jug off and the walls are scored heavy, and internal scoring from sand/grit would suggest to me someone got it running after a swimming event, so now everything is likely ruined; however if all looks reasonably nice then chances are they didn't bother trying to get it running, so a real deep cleaning (splitting as stated, etc.,) may work for you to get this old girl going again....

Be sure to post some pics of the piston, rings, walls, etc.,
 

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Discussion Starter · #14 ·
I'm going to do it! I'm going to crack it open and see how it looks inside!

Dumb question, does the engine need to be removed from the frame for this job? The Youtube videos I found all start with a removed engine, but from looking at the bike it almost looks like it's possible to do it with the engine still in the frame.
 

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I’m good with everything said sofar; gives OP the range of options. @moesother get a bunch of ziplocks and some boxes. Label all the bags with where you removed the parts.
 

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Yep, take the motor out of the frame before beginning. If you have a lot of cleared bench space that'd be real nice... Read up on what you are about to do in relevant sections of the service manual and follow the recommended teardown steps as close as you can. As Goober mentioned get a box of ziplock bags and Sharpies to label stuff as it comes apart. Ask questions... we all love to help.

Worse case scenario is you'll salvage whatever is still good and the best case... well, who knows you just might save it!

Making my popcorn now... :)

EDIT:
You'll need a decent quality set of metric (6-point) sockets. Some of those case bolts and rocker cover bolts might be stuck, so holler if you get in a spot where it feels like a bolt might snap off or round off the bolt head... If you have (or a friend has) a 1/2" drive impact and 27mm socket for the clutches you'll make quick work of this.
 

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one tip is make a 2x4 frame for the motor to lay on when you split it , the manual shows you how to do it , you take all the bolts out but like one or two on the side with the most thru bolts , then flip it over and put it in the wooden frame ,carefully pop the top case half off and everything will sit in the bottom half the case
 

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Discussion Starter · #20 · (Edited)
Thanks for all the tips!

I got the engine out! It went pretty smooth and the service manual was all I needed.

The only tool I was missing was snap ring pliers but I made due.

There was a little bit of water in the front gear case when I drained it.

I had the front of the bike propped up so it would be more comfortable working on it. I think this must have been what caused the front differential oil to spill out when I removed the "propeller shaft".

I was worried about how heavy the motor would be so I jimmy rigged a step latter and some straps to help hold it. It turned out the motor wasn't that heavy and I could maneuver it myself without much issue.

Tomorrow afternoon I'll take a look at making that frame out of 2x4's.

I'd like to clean the engine before I start pulling it apart but all the holes are exposed. I'll try to tape them closed somehow.

 

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