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Discussion Starter #1
OK, here's the deal. My 16 year sons friend purchased an 02 TRX 350FE that was smoking really bad. Seemed to have plenty of compression because it ran fine, just smoked all the time.

I tore the top end down and the oil rings and scraper rings were shot but the cylinder only showed minor wear. The motor was already .50 over so I just ordered another set of rings and put the bike back together. Keeping my fingers crossed, the bike cranked great but smoked. Not as bad as before but very noticiable. I let the bike idel for about 5 minutes and it was smoking the whole time. Disgusted I killed the bike and enjoyed an adult beverage while I scratched my head. When i cranked the bike back up...no smoke. So I let it idle for about 5 more minutes. I though all was good until I rode the bike. About 100 yards into the ride, smoke...profuse smoke...like you poured oil into the cylinder. Tore the top end back down, piston and rings are fine, cylinder the same.

I'm thinking the cylinder will need to be resized, new piston and rings? Any other suggestions?
 

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Valve seals maybe...did you actually do a compression test or you just guessing since it ran?
 

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I would be looking towards the valve train as flcb7 stated. valveseals are getting soft when it runs for a bit and allowing oil to escape between the valve and seal. dropping oil into the cylinder thus causing a mosquito killer.
 

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Discussion Starter #5
Definitely looks like the local mosquito fogger! I'm going to take the head to the local Honda shop for new valves, guides, etc.

I think I'll have someone cross hatch the cylinder and check the bore for irregularities.

I'll keep you posted on the outcome. Sure was wanting to save this kid some money but looks like the new tires he wanted will have to wait for a few months.
 

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I found on older engins over time the valve steam seals will get hard and cause leaking down on the valves. Its a good idea when you do a rebuild change the seals.Unless the moter dosent have alote of hours or age on it.
 

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Definitely looks like the local mosquito fogger! I'm going to take the head to the local Honda shop for new valves, guides, etc.

I think I'll have someone cross hatch the cylinder and check the bore for irregularities.

I'll keep you posted on the outcome. Sure was wanting to save this kid some money but looks like the new tires he wanted will have to wait for a few months.
Why would you break it down that far if it's just the valve train?? Why touch the bottom end if it's not needed since your trying to save the kid some money?? I mean it's a good idea if you want a full rebuild but if the bottom end is fine...don’t fix what aint broke IMPO since you wanna save him money.
 

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You can do the crosshatching yourself just get yourself a bead hoaner and some WD-40 put it on a drill and crank it up then just work the hoaner up and down the length of the cylinder. Done.


Definitely looks like the local mosquito fogger! I'm going to take the head to the local Honda shop for new valves, guides, etc.

I think I'll have someone cross hatch the cylinder and check the bore for irregularities.

I'll keep you posted on the outcome. Sure was wanting to save this kid some money but looks like the new tires he wanted will have to wait for a few months.
 

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Discussion Starter #9
I didn't tear the bottom end down. Only the top. Crank is still in the motor. Just removed the head, jug and piston...again. After running it the first time and it would smoke then stop smoking, then smoke again, I wanted to make sure the ring ends were 120 degrees opposed and nothing else was wrong. I'm a firm believer in don't fix what ain't broken. I pretty much knew that something would have to be done to the cylinder after it smoked erradic. To remove the cylinder is only a couple of nuts and bolts plus the c-clip on the piston pin.
 

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You can do the crosshatching yourself just get yourself a bead hoaner and some WD-40 put it on a drill and crank it up then just work the hoaner up and down the length of the cylinder. Done.
harbor freight sells em...
 

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Discussion Starter #12
Update...local Honda ATV dealership is going through the head now. Valve guides were not in the best of shape and crow is hard to eat but I had the oil scraper and compression rings reversed. I don't feel so bad because the mechanic working on it said that he did the same thing to his own ATV a couple of years ago. When you get in a hurry S--T happens.

Should have the parts back tomorrow or Friday and will put the motor back together Saturday morning
 

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Yup it can happen. I was in a hurry to do a valve adjustment on my older h22 engine and I didn’t tighten the nut down and dropped the valve and put a hole in the piston.
 

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Discussion Starter #15
OK, put the motor back together this weekend. No smoke...until the exhaust pipe got hot then it started smoking and continued smoking after the motor was shut off. It was burning off the oil that was built up from the past Mosquito fogging. We removed the exhaust and muffler, cleaned with a couple of cans spray carb cleaner, NO SMOKE!!! I hope this is the end to a long story.

Thanks for all of the help from those that posted.
 

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Discussion Starter #16
COUPLE MORE THINGS.

Total cost:
$280 - head job, cylinder honed, new rings, new gaskets, new spark plug, cleaned carb since it was off...all labor was free and what can't be measured is that I supervised and instructed two 16 year olds in tearing down and rebuilding a motor...twice.

NOTE TO SOMEONE LOOKING FOR A USED ATV...IF IT HAS A SNORKLE ON IT...RUN DON'T WALK AWAY BUT RUN AWAY. ATV'S ARE NOT BOATS AND SHOULD NOT BE USED IN THE PLACE OF SUCH. I MEAN WOULD YOU PUT TIRES ON YOUR BOAT AND DRIVE IT ON THE ROAD?
 

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COUPLE MORE THINGS.



NOTE TO SOMEONE LOOKING FOR A USED ATV...IF IT HAS A SNORKLE ON IT...RUN DON'T WALK AWAY BUT RUN AWAY. ATVS ARE NOT BOATS AND SHOULD NOT BE USED IN THE PLACE OF SUCH. I MEAN WOULD YOU PUT TIRES ON YOUR BOAT AND DRIVE IT ON THE ROAD?
I watched some videos of some guys at Busco Beach and all I could see was the driver and snorkel. It looked like a sub with the scope up moving across the pond. I think I would pass on one to unless it was dirt cheep
 

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Wait until we all meet up there and you see it first hand...some of those guys when they come out of the holes their quads are 18 to 20 inches from the pegs to the ground! insane.


I watched some videos of some guys at Busco Beach and all I could see was the driver and snorkel. It looked like a sub with the scope up moving across the pond. I think I would pass on one to unless it was dirt cheep
 

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COUPLE MORE THINGS.

Total cost:
$280 - head job, cylinder honed, new rings, new gaskets, new spark plug, cleaned carb since it was off...all labor was free and what can't be measured is that I supervised and instructed two 16 year olds in tearing down and rebuilding a motor...twice.

NOTE TO SOMEONE LOOKING FOR A USED ATV...IF IT HAS A SNORKLE ON IT...RUN DON'T WALK AWAY BUT RUN AWAY. ATV'S ARE NOT BOATS AND SHOULD NOT BE USED IN THE PLACE OF SUCH. I MEAN WOULD YOU PUT TIRES ON YOUR BOAT AND DRIVE IT ON THE ROAD?
GOOD DEAL!!!!!
Make em learn when they are young...it helps trust me. Iv gotten all my engine building skills from LEARNING HANDS ON not in a class room like most ppl. If I can't see it and touch it with my hands then what's the point in learning how to build it?? But that’s me. Some ppl can learn w/o touching anything I can't. On my 1st 2 honda 4cly engine builds I learnd on my own no help. Trial and error for the most part....you live and learn.
 

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Wait until we all meet up there and you see it first hand...some of those guys when they come out of the holes their quads are 18 to 20 inches from the pegs to the ground! insane.
The one I seen looked like he was way off the ground and big ole nobie tires. I cant weight to go.
 
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