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Category Archives: Builds, Projects & DIY
1997 Honda fourtrax 300 4×4
250EX Refresh
250EX Refresh
I bought this a few years ago and did a bunch of work on it; new tires, wheel spacers, frame paint, bearings all around, chain, brakes, etc… I had maybe $700 into it and sold it the first day for $1200!
Wanting to move up, the choices were somewhat slim, TRX250X or Raptor 250. I’m a huge Honda whore so the choice to go with the TRX was slightly biased. Off to scour the interweb for the right one…
I found a lightly used 2013 on Craigslist for $1800. Apparently the owner didn’t really know what they’re worth as most 2007 and 2008 models are going for that much. It was way dirty and the owners 15yr old son took a hammer to the muffle to make it sound "cooler"!
250EX Refresh
I bought this a few years ago and did a bunch of work on it; new tires, wheel spacers, frame paint, bearings all around, chain, brakes, etc… I had maybe $700 into it and sold it the first day for $1200!
Wanting to move up, the choices were somewhat slim, TRX250X or Raptor 250. I’m a huge Honda whore so the choice to go with the TRX was slightly biased. Off to scour the interweb for the right one…
I found a lightly used 2013 on Craigslist for $1800. Apparently the owner didn’t really know what they’re worth as most 2007 and 2008 models are going for that much. It was way dirty and the owners 15yr old son took a hammer to the muffle to make it sound "cooler"!
08 Rancher I picked up
Initially I was going to rebuild this one and resell it, but now the brother in law is making noises about wanting it.
I just put a new top end on my wife’s 420AT, so I think what I’m gonna do is buy a new 500 cylinder and piston, put those on her 420, and put the top end from her 420 onto this one.
Anyhow, plastics need to be cleaned up, racks painted, will tear the engine down and clean everything out, new seals, new top end, new timing chain, then it hopefully will be good to go.
Found A New Project!
Manual shift winch controller
The Unicorn 400EX
Day 1
First up new rear tires.
Next was a thorough cleaning and paint. I decided to pain the plastics with Krylon Fusion. We had good experience in the past and I knew it wouldn’t be long before I’d be getting some new plastics.
The stock rims were used up pretty good so I decided to pick up some steely’s from ITP for the cost.
All plastics painted. Now off to the do the seat. I used a vinyl paint from Autozone. It worked pretty good. It does rub off but nothing you can’t touch up.
Ok, so here it is. Never did a paint job like this before. My son loves camo so I figured what the hey. He loved it so that’s all that matters.
Got the new tires mounted on the wheels. Went with something cheap on eBay for wheels and they are doing quite well so far.
The camo had to go and quick. It was fun but I really like the look of a racer type ATV. I’m always watching racertv and just enjoy that type of look. So I decided to go back to flat white and put on some racing numbers and stickers.
So now the fun begins. Enough of the cosmetic stuff. The clutch was toast. I ride pretty hard so 3 months in it was slipping pretty bad. Along with that, toooo much riding on the rear tires wore out the rear bearings so I replaced the carrier. And while your down there you might as well do the chain and both sprockets. This was my first time ever attempting something like this so it was very nerve racking to say the least.
Old Clutch
Had the old gasket machined off at a local automotive shop. These guys were awesome and have dealt with them before. They didn’t even charge me!
New clutch in, all buttoned up. I went with a Tusk HD clutch with springs. So far it’s been handling all I can throw at it. I ride mostly trails.
Installed some performance scoops to keep things more cool.
So at this point with the new work it was set. Then on this ride I noticed a horrible tick, louder than normal.
I went right home and did some research on valve adjusting and timing chain replacement. I purchased the valve adjustment tool after getting some local quotes to do a valve adjustment. Oh at this point I also purchased a Cylmer service manual which worked well for torque specs on the clutch. It turned out the valves were just off a bit and tightening them up got rid of that tick.
So with the valve work done and the atv back to sounding like normal it was time to move on. While researching valve adjustments I accidentally ordered a whole mess of parts, I’ll try not to forget some stuff.
- ProTaper Clutch Perch
- Tusk Clutch Cable
- Tusk Throttle Cable
- New OEM Carb
- Big Gun Evo R Slip On
- DynoJet Jet Kit
- Uni Air Filter
- Maier Plastics
- AllMotorGraphics.com Graphix Kit (Custom)
Again, link to the full Google Album.