HI all. i looked on other forums and could not really find an exact answer for this.
My neighbor, who is incredibly hot headed 🙂 gave up on his 2000 Recon because it started smoking and he just gave it to me. thinking in was a piston, i rebuilt the top end (replaced the piston, rings, cylinder gasket and head gaskets and also rebuilt the carb). Its runs great BUT….after everything heats up there is a discernible "tap" that develops in the top end. No smoke, no loss of power…just a tap that sounds like a piston tap. I have a 2004 recon and it does this kinda sorta slightly but nothing to the level that the 2000 is doing. i have about 2 hours on the rebuild. any idea what i did wrong? or what it may be? Ill try to post a video/sound file later today

HI all. i looked on other forums and could not really find an exact answer for this.
My neighbor, who is incredibly hot headed 🙂 gave up on his 2000 Recon because it started smoking and he just gave it to me. thinking in was a piston, i rebuilt the top end (replaced the piston, rings, cylinder gasket and head gaskets and also rebuilt the carb). Its runs great BUT….after everything heats up there is a discernible "tap" that develops in the top end. No smoke, no loss of power…just a tap that sounds like a piston tap. I have a 2004 recon and it does this kinda sorta slightly but nothing to the level that the 2000 is doing. i have about 2 hours on the rebuild. any idea what i did wrong? or what it may be? Ill try to post a video/sound file later today

I was wondering if anyone is having similar issues with the shifter. At times when I stop and want to go into neutral I have to press the button several times to get in to neutral . Also a times when I’m in reverse and trying to get out of it the same thing. Need to keep pressing the button several times before I get it out reverse then to neutral. Any ideas on fixing this problem if any ?

Thanks

First off, I’ve been a member here for a few years and have found lots of great information here. A couple weeks ago I was getting the quad ( 2004 Honda Rubicon TRX500FA) ready for as hunting trip. I must say it was sitting for about a year and a half. I put a new battery in it and it started, then died at the same time I caught a whiff of bad gasoline.

First issue: Pulled the carb apart for cleaning and after I put it back together it ran great, or so it seemed. The first problem is that when going downhill for more than a couple hundred yards it will sometimes spit, sputter and die. I couldn’t narrow it down if it died more often on steeper down hill with more fuel in the tank or less steep with less fuel or vice versa. It will start up after sitting for about 5 minutes and run great just like it never happened. I don’t know exactly what the problem is. It doesn’t matter how much fuel is in the tank from almost empty to 3/4. I am thinking it could be a sticky float, float valve or maybe even the lower part of the in-tank screen set could be clogged and when going downhill the fuel level in the tank is below the clogged portion of the screen. Could it be the throttle position sensor? Any ideas where to start?

Second issue: The engine stop switch has to be moved slightly left for the engine to turn over. If it is in the center position on/detente the engine will not turn over. Is there a way to fix the switch? The only way I have found to replace it is to buy the entire left handlebar switch assembly.

Thanks in advance

Damon

I got an 06 rancher not too long ago and the weekend before the mud bogs it wouldn’t start. Brought into a shop they cleaned the carb and it fired right up again. Brought it to the mud bogs, didn’t go deep just drove around the edges of the mud holes a little while I drove around the park and watched. My exhaust started to smoke through out the day and at night it was really bad and when I was driving back to my campsite it stalled out and I checked my oil and there wasn’t really any left. I added oil again and it still won’t start, Any ideas why?

the oil change indicator came on on my atv,so I changed oil and filter.The indicator however stayed on,is this as simple as disconnecting battery or is there as sequence to remove the oil change prompt?

Hey guys. First post here. Ive got an issue here with my brand new Rancher that I was hoping to get some help on.

First the particulars: I have a brand new 4×4 rancher. I got it about 5 months ago from a dealer and it currently has 35 hours / 307 miles on it. All of my riding has been on dirt roads mostly pleasure riding. It has not been abused at all, and is garage kept. It is the 2015 Rancher TRX420FM1. The base 4×4 model, with camo paint scheme. Ive not modified anything.

Now my problem: I was riding the other day down a dirt road, just cruising in 4th gear when I looked down and noticed the speedometer was wrong. It was showing my speed about 10mph too slow. I slowed to a stop and began testing each gear, and just watching the speed, trying to figure out what could be going on. I noticed that the speed would read accurately at certain engine RPM’s and then it would just drop several MPH on the speedometer even as I am still accelerating. I came home and began researching where the speed sensor was, because that was the first thing I wanted to check. I finally found where it was located, so I simply unplugged it for a minute then plugged it back in. I took it out back into my horse pasture to test it and it appeared to be fixed after doing this. Speed seems accurate in 1st, 2nd, and 3rd gear, but as soon as you get around 20mph/4th gear it seems to start acting up again. In 5th gear, when I open it up wide open I would expect the speed to top out at 53mph, but the speedometer will read well below that, not even 40mph.

I finally decided to take the screw out of the sensor and pull it competely out to look at it. It had a little engine oil on it but otherwise it looked fine. I cleaned the plug contacts, and then traced the wire and cleaned every plug contact when I came to a plug. I put it all back together and am still having the same problem. Im at a loss. The 4 wheeler seems to run completely normally – I notice nothing else that would suggest any other problem. The speedometer seems to be accurate up to about 20/22 mph when you go into 4th gear, and then its like 8-12mph low from then on. This is of course throwing my odometer and trip meter’s off.

The only thing I worry about is that Just before I went on the ride and noticed the problem, I moved some Hay with the 4 wheeler into my horse pen. It is a round bale, and the way I move it is by pulling it on a pallet which Ive turned into a sort of sled by screwing poly tubing all along the underside. The bale weights likely somewhere between 600 and 1000lbs. I have a 2" ball on the rancher and I just loop the high tensile wire around the ball and pull it into the pen. Its less than 100 foot it has to pull, but this does put a lot of stress on the 4 wheeler. I use 4 wheel drive for the pull. My pallet dug in just as I entered the horse pen and the 4 wheeler just began spinning tires and bounced a little trying to pull it. I immediately stopped and left it there. Ive moved hay like this once before and didnt have any issue. I am aware this likely exceeds the weight limit on the rear axle, and this shouldnt, in my mind, have any thing at all to do with the speedometer messing up. Ive decided not to move hay like this again to be safe. After I moved the hay is when I decided to just ride down the road a little as the sun was setting. Thats when I noticed the problem.

Ive went online to try and find an OEM speed sensor replacement but have had no luck, and Ive searched probably a dozen parts sites at this point.

Any info would be greatly appreciated. Sorry for the long post, I wanted to detail as much as I could here.

It’s finally fixed. After testing tons of wires, relays, and fuses. Initially when we blew a fuse by cutting into the orange 4wd wire we replaced that fuse. But what we did not realize was that it must have been going into 4wd in the middle of the blown fuse and it was stuck there. We figured this out by my nephew made the bike go into 4wd by bypassing the computer and everything. So soon as we heard it go into 4wd it started working. It was stuck. Now it works like new. And the winch works….😃😆 I really appreciate this website, it really helped. KENTCO AND SHADETREE thank you!

hello I have a 1999 trx 300 that will not start electrically it kick starts and will start if you jump the solenoid the solenoid is new but it is only getting 4 volts instead of 12 volts to activate the solenoid any ideas would be appreciated.

shop said it jumped time and is dead , its a 2000 250 recon where is the best place to get a cheap used motor ?:blink: