Category Archives: Repair & Maintenance

Spark Arrestor bolt won’t come out.

The spark arrestor bolt on the underside of the muffler on my 2014 Rancher will not come out for anything. I don’t have a torch so I didn’t try that but I’ve tried pretty much every thing else.

I’m about to hit 100 miles and wanted to clean it out. Any suggestions on getting the bolt out? I’m going to have to get a new one since I’ve chewed this one up pretty good.

Wayne

2005 Rincon, Hard to start and no power

I am having problems getting my 2005 rincon 650 running… I bought it a few years ago used. When purchasing it ran great no issues. Paid and loaded it in the truck. When I got home it wouldnt start, after tinkering with it for a month and not figureing out what it could be i give up (Also have a 03 thats perfect). I let it sit for about a yr and start messing with it agian. I find out that the timing has jumped, chain is no good along with tensioner. I replaced the tensioner with a manual one as a temp fix to make sure everything else was working. I had a lot of problems with it when trying to start that where different… it had a very hard time starting, like to much compression or a dead battery. but the battery was brand new fully charged. I pulled the head checked the timing and noticed that it was off. Once i reset it correctly i put everything back together and found not 1 but 3 head bolts were stripped. I got it to tighten as best as possile. Now the motor will turn over with what sounds to be normal, unless i have the choke on. then its back to having problems turning over… But if i get it to start it idles fine, everything sounds fine, but there is no power… i mean like 10mph is top speed. no bogging or anything it just seems to quit going after that. and thats with full throttle… there are many more things I could list but would love help with one thing at a time, if this thing is even fixable… I have made sure on the timing maybe 10 times, I tried to check the oil pressure but cant get the thing to start again. Can anyone help me? Ive looked all over and cant find anyone having any issues like this. Thanks

2005 Rincon, Hard to start and no power

I am having problems getting my 2005 rincon 650 running… I bought it a few years ago used. When purchasing it ran great no issues. Paid and loaded it in the truck. When I got home it wouldnt start, after tinkering with it for a month and not figureing out what it could be i give up (Also have a 03 thats perfect). I let it sit for about a yr and start messing with it agian. I find out that the timing has jumped, chain is no good along with tensioner. I replaced the tensioner with a manual one as a temp fix to make sure everything else was working. I had a lot of problems with it when trying to start that where different… it had a very hard time starting, like to much compression or a dead battery. but the battery was brand new fully charged. I pulled the head checked the timing and noticed that it was off. Once i reset it correctly i put everything back together and found not 1 but 3 head bolts were stripped. I got it to tighten as best as possile. Now the motor will turn over with what sounds to be normal, unless i have the choke on. then its back to having problems turning over… But if i get it to start it idles fine, everything sounds fine, but there is no power… i mean like 10mph is top speed. no bogging or anything it just seems to quit going after that. and thats with full throttle… there are many more things I could list but would love help with one thing at a time, if this thing is even fixable… I have made sure on the timing maybe 10 times, I tried to check the oil pressure but cant get the thing to start again. Can anyone help me? Ive looked all over and cant find anyone having any issues like this. Thanks

94 trx300fw 4×4 rear axle housing

So I’m about done with my build and realized I don’t have the spring that goes in between the drive shaft and the diff to keep tension… I’m told I need that!!?? anyway I’m looking at the manual to make sure I have all the orings and notice that the rear axle housing needs it’s own orings or so it says in the manual but the parts diagrams dont show?? as well as the obvious ones for the diff and the brake housing but when I look it up they do not have a part number but i notice there the same size as the front of the diff to swing arm oring?? Any help would be awesome and do I need them?

2015 Problematic Rancher

I recently snorkeled my 420 and got 28" tires for it. In the past week, the fuse blew for my Radiator fan, overheated once, and everything has been downhill from there, first, my Display started acting strange, then moisture accumulated within the protective cover. Then, it wouldn’t start, All that was heard was a clicking noise, so I replaced the BLACK relay in the compartment under the ECU and now it won’t even start. When I turn the key, nothing happens, nothing indicates that it is even on. Before I replaced the relay my Display would come on and stay on, now, nothing. BUT when I bypass the starter with a screw driver it will turn over but it will not start. And it will not crank without bypassing the starter solenoid. NEED HELP ASAP!! Looking for a true ATV Mechanic’s help. Thanks!

2015 Problematic Rancher

I recently snorkeled my 420 and got 28" tires for it. In the past week, the fuse blew for my Radiator fan, overheated once, and everything has been downhill from there, first, my Display started acting strange, then moisture accumulated within the protective cover. Then, it wouldn’t start, All that was heard was a clicking noise, so I replaced the BLACK relay in the compartment under the ECU and now it won’t even start. When I turn the key, nothing happens, nothing indicates that it is even on. Before I replaced the relay my Display would come on and stay on, now, nothing. BUT when I bypass the starter with a screw driver it will turn over but it will not start. And it will not crank without bypassing the starter solenoid. NEED HELP ASAP!! Looking for a true ATV Mechanic’s help. Thanks!

Rancher 350 neutral light always on in every gear

Hi guys, Working on a 2000 350 Rancher manual shift only, that came in with an odd condition. It felt to be stuck between possibly high gear and neutral (neutral light on but wont roll forward and takes off when you get it started). Start it up and it acted as if its in gear but the neutral light is always on. I pulled the front case and found a broken shifter paw, replaced that and checked both clutches. Everything looked to be reusable all were at or above the minimum spec so at the very least it should operate this way. I started the bike up and dropped it into 1st gear. it felt and sounded as if it shifted in to gear but the green neutral light was still on and no forward motion. The trans feels as if it shifts up and down through the gears through neutral and into reverse, it jumps lightly back and feels engaged in reveres but the neutral light remains and no red reverse indicator. It almost feels like a bad clutch but I cant understand why does the neutral light is always on. what controls the neutral safety? could there also be a shifter drum issue?