Hello all, new to the forum and just picked up an 03 rancher 4×4 manual shift. After a couple hrs of my sons and I joyriding around the yard we parked it in the garage for the night. The next day after pulling it back out I noticed a baseball size oil spot there and a drop or two in the driveway where it was sitting. Looking underneath there was oily dirt around the bottom of the recoil assy and the bottom of alternator cover. The only place there was a drip was on the plastic cable clip under the recoil. I’ve read that the oil seal will leak when dirt gets in there so I took off the recoil assy and it looks pretty clean. I didn’t remove the nut with my impact yet because it was getting late last night but I’m wondering can the seal still fail without being corroded from the dirt and mud or should I look at replacing the gasket on the alternator housing since I’m what looks to be halfway there? Anyone have to change that gasket for a leak? Thanks for any advise.

I have replaced stator, regulator, and cdi. Still no spark? The stator ohms when touching pink and yellow wires is 2-3 ohms on multimeter. Is this too much? Is it broken? And when i crank it no output voltage between pink/yellow and ground. Any ideas? Please help!!

I am trying to teach myself how to rebuild the engine all the way. I have the crankcase split, cleaned and my service manual open on an old crappy iPad for reassembly. I think I finally got the transmission installed in the proper sequence but the shift drum and shift forks are a BITCH to line up. Does anyone have a tip for making that easier? Does it matter what position the drum is in? I have to guess as long as all 3 shift forks are placed in order and aligned in the shift drum grooves that I have it done right??? Is that correct??

I get a sinking feeling that it’s "off" but all the gears turn smoothly…..is there a way to test ability to shift gears w/out putting half the engine back together??

Thanks for any feedback !!!

As title says I’ve got a 1986 Honda FourTrax trx200sx.

I purchased knowing when it runs for a few minutes it stalls out unless you give it some throttle/gas… So adjustment didn’t work and I tore apart the thing to get to the carb (not sure it was suppose to be so hard but every screw/clamp was printed in a direction I couldn’t access!).

I get carb opened up to see a bowl of red liquid and red flakes so I think I figured out why it stalls!???!!

Now I cleaned it up although I’ll need to order a rebuild kit and probably get an extra aftermarket carb as it looks like my tank is going to be a big project..

My first problem, I got the petcock off but there is still a rubber hose/gasket (gasket is black and rubber hose used to be clear probably) that I can’t get out of the tank. Does anyone have suggestion on that? It’s going to be bad enough to get the rust out of it, but I’m worried those parts will be ruined if I use a cleaning product/sealant on tank.

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So I just had to replace the crankshaft on my 400ex. Took everything apart, replaced it, and put everything back together. Something isn’t right though:

-I cannot get the wheels to move no matter what I do
-If the clutch is in, it starts right up – if i let off the clutch it dies
-The back tires are locked, whether I have the clutch in or not – and I can’t find neutral
-It seems to me like I can shift down to first, and up to either neutral or second (can’t tell which because the tires are locked regardless), but occasionally the shifter is just stuck and I need to tap it several times to move.

Does anyone have any ideas what the issue might be? More specifically, could it be anything that won’t involve me taking the whole thing apart and splitting the case all over again? I’d like to try any possibilities before I tear it all down as that’s relatively time consuming

Thanks in advance!

So looking at the front diff I tore apart, initially I thought I could simply clean it out and replace all the bearings and seals, but the front clutch housing that the pinion gear slides down in has a roughness to it when I turn it. Pinion gear is out, and the pinion bearing needs to be replaced. I’m talking about spinning the other end of the clutch. Is there a bearing in there or ???

Part #17 here

Honda ATV Parts 2006 TRX500FM A FRONT FINAL GEAR Diagram

I have 99 400ex replaced stator, regulator, cdi and still no spark. The stator has like 1.8 ohms inbetween yellow and pink wires. Is this too much. Could i have gotten bad stator? No spark to coil bl/y wire. Tore apart whole harness looks good. Pwr to rectifier and cranks over. Help please!!

Luckily I had an extra front diff in the shop.

Got this 06 Rubicon for the father in law last week. Drove it around a bit before purchasing, and it drove great. Had an error code 5 on the shifting that was irritating but the wheeler was cheap, so I told him to get it.

Got it home, reinitialized the computer, and the error code hasn’t come back up. Sammich maker and I took it for a ride on the farm and I noticed the front end was noisy when I put it in 4wd.

Jacked up the front end and figured out it was in the diff, so pulled it out last night. Axles were STUCK. Had to pull the diff with axles still in it, and after hammering and prying for an hour I finally unbolted the diff halves and basically hammered it apart (at that point I knew the diff wasn’t going to be good without major work, and I had an extra, so I said F it).

When I pulled the pinion and acuator, ball bearings fell out everywhere. Inner race stayed on the pinion, outer race in the clutch housing.

Ring gear bearings feel like they’re full of sand, and have a ton of play in them.

Luckily the extra diff I had is in great shape. Cleaned up axle splines and will hopefully get the new diff in tonight.

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I can hold the starter button and it turns over great but will not start unless I just give a short burst of the starter or it will start great with the pull cord. stator problem?

Hey guys, cranked my 91 fourtrax this afternoon and decide to turn on the lights. I noticed one headlight was dimmer than the other and they both "pulsed" with the engine idle. What would cause this? I just put a battery on it and it cranks fine. Thanks