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Hey im kinda new here....i have a 1991 trx 350 fourtrax ...canadian model only... i rebuilt the thing head..valves..timing chain...clutches...one way starter bearing...gaskets....etc...i also replaced the start switch with lights and kill switch i got the switch new for a 89 trx 350 it was the same on appearance but when i got it it had 6 wires instead of 7 they joined 2 into 1 ....so i coppied the exact thing and connected the same colour wires. Now the fuel pump wont work.....unless theres direct power.... and i have no spark. Ive spent to much into this thing and id like it running already......can someone help?!?!
 

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The replacement handlebar switches you put on the bike may be wired wrong, since you mentioned it wasn't a plug & play direct fit.

You should have battery voltage passing through the kill switch when you turn the key on with the bike in neutral. I would unplug those handle bar switches and sort out which wire(s) are connected wrong. The Ignition troubleshooting section of the FSM covers this and the wiring diagram in the FSM for your bike may be a useful reference too.



Let us know how it goes...
 

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On 1988 & up TRX350s, Honda added what they termed a "Revolution Research Line" to the DC-CDI ignition circuit. It detected whether the motor was cranking over or not before energizing the ignition and the fuel pump relay for added safety.

My guess is you got a handlebar switches assembly intended for a 1987 DC-CDI (those lack the RRL) because those fit no other year model.

Or in a worse case, an '86... which would blow the ignition fuse as soon as you turn on the ignition switch if that were the case....
 

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Discussion Starter #5
Thanks guys ill try it. But i may just see if i can get a new switch made for that model......my mechanic brother moved and i have no use for wiring.??
 
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