Category Archives: Builds, Projects & DIY

Light Bar on a 300

Hey everybody this is my first post here so if I’m in the wrong place I apologize. I have a 1999 300 fourtrax 2wd that I want to put a light bar on. Once I get the light bar on I won’t be using the stock headlights. I saw on youtube where a guy hooked one into the stock headlight switch. What I’m asking for is pointers and how best to go about hooking them up and whether it’ll work or not.

These are what I’m looking at-

Amazon.com: Premier Light Bar – 12" CREE Flood/Spot COMBO Beam 72w LED Light Bar Off Road UTV: Automotive

http://www.amazon.com/120w-Light-Com…/dp/B00FJQLP7W

1982 Honda ATC200

Been a while but I recently picked up this 1982 ATC200 (for only $250!!) that an old guy had sitting in his garage that he hadn’t ridden in 10 years…..It’s got a plastic desert tank, pretty much new tires and best of all he kept the registration current so no back fees! I put some gas in her and she fired right up! He had thankfully stored it without any gas in the tank but it does need a little work. Right now if you give it full throttle it does (gonna clean out the carb and put in new jets) and it doesn’t seem to want to stay in neutral so trying to push it into the garage or off the trailer is a big pain in the ass.

So my question is this, why won’t it stay in neutral? I know there is a neutral shaft/switch because I can see when it engages but as soon as you start to roll it forward it clicks and goes into first….

And now for some pics:

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Sitting in the garage with my ’86 Fourtrax 350

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88 Almost Completely Restored

Bought this 88 2WD 300 off my neighbor for $500 and it was a junkyard quad if I’d ever seen one. Aside from the engine, almost everything needed replacing. Six months later, she’s just about fully restored. Now I just have to figure out how to remove a few welds. The very first owner, genius that he was, decided to weld the rear cargo rack, muffler and brush guard to the frame rather than pickup some hardware at Home Depot. I had to grind the rack and brush guard off but but the actual welds remain. And I can’t put the new racks and muffler on because the welds are right where the hardware goes. I wanna just grind the welds off but they are pretty much flush with the frame and I’m worried about damaging the frame, as I’m not too skilled with the grinder. Plasma cutter? Hammer and chisel? Anyway, here are a couple before and after photos. The 25 in Mud Lites and aluminum ITP SS316 wheels really complete the look. As we used to say in the 80’s when I was in junior high school, it’s lookin Boss! Lol.

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Bike hoist / table ?

Got this thing today , local mechanic shop cleaning out , hooked up the air and lift the back end of the Dodge off the ground —–thinking a platform /table and this thing should pick up the bike and be a work table , anyone have anything like that or have any ideas on making it work

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96 trx 300

I’ve got a new project 96 trx300, the vin indicates it is a fourtrax, but I’m unsure of the difference. It is 2wd and is in need of both body work, electrical, brake, and I’m sure other things I haven’t gotten into yet.

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So the plastics are pretty much shot, but I’m going to get her running and see where I am.

This is my first 4 wheeler, but I’ve ridden dirt bikes for 20 years and have rebuilt about a half dozen Japanese bikes (mostly Hondas) so I’m not concerned about the task.

I just picked her up last night and haven’t done much but make sure she has good compression and take a look at the serious rats nest of wiring (apparently two owners ago had a switch wired in instead of a key)

Wish me luck. I’ll pick up a filter and oil today and get a good look and hopefully get her to fire later this week.

96 trx 300

I’ve got a new project 96 trx300, the vin indicates it is a fourtrax, but I’m unsure of the difference. It is 2wd and is in need of both body work, electrical, brake, and I’m sure other things I haven’t gotten into yet.

Click the image to open in full size.

So the plastics are pretty much shot, but I’m going to get her running and see where I am.

This is my first 4 wheeler, but I’ve ridden dirt bikes for 20 years and have rebuilt about a half dozen Japanese bikes (mostly Hondas) so I’m not concerned about the task.

I just picked her up last night and haven’t done much but make sure she has good compression and take a look at the serious rats nest of wiring (apparently two owners ago had a switch wired in instead of a key)

Wish me luck. I’ll pick up a filter and oil today and get a good look and hopefully get her to fire later this week.

Right side cover r & r

Hi guys OG here,

My 91 fourtrax was needing an oil change and so i decided it was a good time to remove the right side cover and clean the oil screen. After all how hard could it be. Well the first thing that I noticed was as I was removing the cover the mark that I made on the spline for the kick started rotated 90 degrees as I was sliding off the cover. Next the entire kick started assembly was being removed with the cover. And of course when I finally did get it off I had several pieces that were not where they were originally, Got most of the put back figured out, I think! Kick starter goes back in and the return spring hooks over an "ear" in the casting. However, can’t set the reference (marked where the kick start lever was attached) mark where it was originally. Also the clutch lifter plate, clutch cam lifter and the ball retainer were laying in the bottom of the cover as well as a flat washer. Think I know where they go but not sure which side the spring goes on at the ball retainer. Advise and help from the group would be appreciated. Not sure about the parts staying in-place while I replace the cover either. Oh and the screen was pretty clean to boot!

Thanks for your help, again!

Redoing brush gaurd mount

I was working on the brush gaurd on my fourtrax 300 the other day and when putting it back together, one of the bolts sheared off. So I took the other bolt back out to inspect it, then proceeded to put the second bolt back in and it sheared off. what I want to know is how I can get these two out. I have been told to put a nut on the little bit that is sticking out and weld it on with a wire welder just to get it out. Will this work? What are your ideas? If I can’t get them out then I’m going to weld some flat stock on and move th mount forward about an inch.

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Redoing brush gaurd mount

I was working on the brush gaurd on my fourtrax 300 the other day and when putting it back together, one of the bolts sheared off. So I took the other bolt back out to inspect it, then proceeded to put the second bolt back in and it sheared off. what I want to know is how I can get these two out. I have been told to put a nut on the little bit that is sticking out and weld it on with a wire welder just to get it out. Will this work? What are your ideas? If I can’t get them out then I’m going to weld some flat stock on and move th mount forward about an inch.

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Replacing valve seals

Ok finally got back to the project: my 88 trx 300a. I removed the rocker cover, and used an adjustable spring compressor to get the keepers out. Removed the valve seals. Now I need to get some new ones. The guides feel good and tight. I stopped by the local mega dealership. There is no gasket for the rocker cover. What do you all use? Honda bond? Whats an equivalent? Also the adjusting covers had to come off to get the bolts unscrewed from the cover. Those gaskets are listed at $31.00 each !!
Guess I’ll be surfing for better prices today!