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Very true, that maybe a warning sign, but first it would be ignition fuse blowing .Went for short ride...wow, like a new machine, idles sweet, plenty of power, so happy, showing 3,250 miles in 14 years..thanks again guys.

SUCCESS!!! I got in new OEM PCM today, along with OEM coil (x2), relay and idle air control valve, cranked right up and idled beautiful, coil stayed cool, no blown fuses. Thank you EVERYONE for your input and knowledge and motivating me not to give up..all back together so ride later after grass mowing..once again THANKS to you all who also put up with my whining lol...guess this thread is DONE..maybe it will help someone in the future, I know personally I learned ALOT about my machine.

Yep, I had a Rubicon and an aftermarket top end gasket set. Gave me fits trying to get the valve cover on as the aftermarket gasket wasn't stiff enough to hold up the push rods. The OEM gasket make it MUCH easier to do.

Thanks, I was trying to save a couple of bucks, but in the long run it's costing more !

oem all the way, stay far...far away from any after market parts, when you can get oem. if and when it comes time where we can't get oem anymore ?, then i will use china junk ( we won't have a choice ), until then, i will use oem all the way !. just ask jeep69 what he went through awhile back when he tried using a after market head gasket ?!!..lol.

This is a chart of HP Make/size Horsepower Lowest ratio (final:1) The numbers after the HP is the gear ratio Recon 250 15.5 HP 36.8 300 Fourtrax (after 1988) 16.5 HP 55.0 300 Fourtrax (1988) 18 HP 55.0 350 Rancher 21 HP 54.1 350 Foreman 24.5 HP 57.2 400 Foreman 21 HP 56.9 420 Rancher FM/TM 26.5 HP 46.5 420 Rancher AT (IRS) 27 HP 38.8 450 Foreman 24 HP 56.9 500 Rubicon 33.5 HP 58.6 500 Foreman 27 HP 51.0 500 Foreman (FI) 28 HP 53.4 650 Rincon 35.5 HP 17.7 680 Rincon 38.5 HP 17.7 420 Vs 450 HP

Tires for the truck. The sipper may be down for the count, blowing oil out from somewhere. Yea I know what tire threads do to undies around here….. kinda why I wanna start one…..

Hi @Kyle9076 I would say it's the capacitor for the pull start -- just unplug it -- tape it up good and plug it back together

Hey everyone! Just posting an update. These kids keep me so busy I hardly have time to get anything done.. I started getting into it this morning but went no further then the valve cover. At tdc on comp stroke intake clearance was .005 and ex im thinking was around .007mm. Didnt have 007 on my gauge but 6 glided through easy and couldnt have taken much for .008 to slide in. Got them both at .005 and it no longer sounds like its about to grenade. I did notice it still has the slightest chatter.. when I revved it up once I seen the exhaust heat shield vibrating enough to move.. its missing a bolt on left side. Im really hoping that’s the rest of the noise im hearing. Plan on taking it off tomorrow just to see.. will try to get a vid too. Keeping my fingers crossed it’d sure be nice to putt around through the summer without having to tear it down.

Found the issue it was the fuses under the handlebars the harness was not connected properly thanks for the info

That's what I did with the wife's. I actually had a 420 footshift with a cracked cylinder, so I had the wife's 420 cylinder bored and used it on that footshift, and bought a new 500 cylinder for the wife's. I wonder what the 520 would do? Looking at the chart @Melatv posted, the HP difference in the EFI 500 and 420 is negligible, but you're only actually going to a 475. A 520 would be almost double the CC increase of the 500 cylinder.

and that my friend, is how it gets you every time !..folks want to save a few bucks, when in the long run, it always..ALWAYS ENDS UP COSTING THEM MORE MONEY AND TIME !.

I hear that, i did try to get him to buy a bigger machine, but the kit he found online was a lot cheaper than buying another wheeler. The difference in power was deff noticeable. I have video proof! Honest! 😹

it truly boggles my one brain cell, trying to figure out why atv owners who ride an utility atv, want to '' get that one extra hp '' ?!..lol. you can only get so much from these machines, after that..its all over but the crying. soo..bottom line: don't bother trying to get 100 hp from an engine that is designed to give you 10 hp..lol.

Awesome, happy for you..yea, meltav helped me take the ECM plunge with the green coil wire to ground test, amazing to think NON OEM can wreck such havoc, here's to many trails and memories 😊

It is a rubber material and very flexible. About 3/16”. I wanted something thicker but the thicker mat that was in the store already was cracked as it was rolled up and would probably rip easily on the trail. I haven’t trail tested this hard yet so I will see how it holds up and report back after deer season starts in August.

My old flares were crumbling and I didn’t want to pay the high price of new ones so I made my own from a Home Depot floor mat. It was $25 so if it doesn’t hold up no big loss. I may opt for some thicker material if I can find it. Overall I was pleased with the result for my hunting rig.

Welcome aboard. Post up a pic of your meter on with the headlights on so we can see what you have. @AKATV will be along shortly.

Thanks guys! Got it fixed up.

I like the way they look. I need some too for a forman ,but don't want to pay the high price. I'll probably make some . Is that some type of rubber or plastic?

She’s all back together and I got the heat cycles done just need a chain FullSizeRender.MOV IMG_4134.MOV IMG_4138.MOV

Earl from ? Ya think maybe a rear main or front ? ...if its the 350... i dont think ive ever seen one that doesnt weep around the valve covers... least back in the day.....and I like the way you think.... You'd make a good professional PITA... maybe shade is right ? Maybe we be distant kin...i know one thing... two of us wont be good for this place..... when done we can leave a marker where this place once was....lol!

Yer welcome....Tires for the gas sipper ? << (writing that one down) ... need i remind you tire threads here.. can cause some people here to come completely un hinged... lol....ill sure be tuned in for that thread..... 10-4 on the leak free (thumbs up)

It does look like a warm coil might point to a bad ECU on these EFI machines, as that Foreman was doing the same thing.

I’ll take a look at it, thank you! This has been on the back burner for a bit, had my gas sipper break down on me and the truck has to have tires to pass this year’s inspection so I’ve been dealing with those issues….. might start a tire thread for the truck lol. The good news is my effort seems to have paid off, the Bridgestones have been leak free as far as I can tell, and look great in my opinion.

Been a minute since a update but got all new billet internals flywheel a flattop piston and new carb waiting on the cam to get there then it’s time to put it back in the bike

Got another PLASTI_DIP video... and it's on chroming this go round and i think they have nailed it! The test samples Look great!... i'll send ya via PM.....

Glad to see you made it over here, welcome to the forum! Seeing how these will run without a meter even plugged up to the machine, the mystery deepens If this was a Honda dealership and they broke your meter plug because they did not know how to get it apart, that alone speaks volumes about their service and technical proficiency. I would be hitting them up for the cost of a replacement plug and or meter or see what they are willing to do I can repair it for you anyways, but it wont impede function the way it is, you just need need to keep it waterproof for now As far as you ATV issues at this point we need to confirm, that you have spark, fuel, and compression Other members will be along to help soon as well -AKATV

My ES is too dang reliable and I find myself with extra time on my hands, time that others seem to use working on their machines. For us ES owners, what do we do with that extra time? Please and Thank You. WM ES Owner

Thanks for the add, looking fwd to being a member. Steve

Thank you for trying, shadetree I just cut the end off the muffler and spent the day creating some baffles out of sheet metal and just got it all put back together works great Welding is functional, not too good to look at “A grinder and paint makes me the welder I ain’t” -AKATV

Well you did more than catfish originally asked you to do, as usual there is always more to fix when you get it running. Somebody must want a good old Honda sports bike.....

Took it for a spin and got 1/2 down the street and it started running like crap. i thought “Now what?” but it would smooth out with starter fluid, so I drained the tank and put some fresh gas in, and after feathering it for a few minutes it smoothed up and ran great. Took the mini-me out on the farm, dug out a beaver dam to make her a “waterfall” and it did fine on that trip, so back to the owner tomorrow Thanks again for the input guys!

advice is free...parts are not !..lol. first off, complete engine gasket kit. tube of yamabond ( for where there is no gaskets ONLY ! ). all engine oil seals, D.I.D. cam chain is what i install in all my builds. 3 qrts of atv oil, oil filter, spark plug. air filter. only spec tools you will need: valve spring compressor ( if you do not have one ? ). flywheel puller, centrifugal clutch puller tool. a seal puller ( but not really needed, but works easier than prying seals out with a screwdriver ). service manual for sure !!. have your camera ( cell phone ) on hand to take lots and lots of tear down pics, before, during, after. this way, if you get stumped?, you can always go back, look at pics to see where that thrust washer goes ?..lol. if it were me ? ( i know its not..lol )..i would replace the main crank bearings while you have it torn down, yes..its extra money, but i would do this now, and be worry free for a few more yrs !. a good metric socket set, brass hammer, pry bars, air compressor, air impact gun ( 1/2 ), deep impact sockets, you will need 27mm, 24mm, 22mm, here and there. you can never have enough impact sockets !. some cases, you will need a 30mm, 29mm, 28mm. these come in handy for the hub nuts. not needed, but handy..A PARTS WASHER !. this comes in very handy to rinse out the cases once you get it all part, yes..i go that extra mile when i build my engines. if you get stumped ?, we are always here to help !, myself..i also do phone support..lol.

Okay, not quite what you think, but it is a Honda. Have some friends who are back in country do to some unrest where they've been serving as missionaries for the last almost 40 years. Had a very short amount of time to get out leaving their business and belongings behind. Back in the states til August of next year while they regroup and make a new plan. While here they are going to need to do some traveling to raise more financial support. So will be doing that over a fair amount of this spring and early summer. Their travels will take them all over the U.S. so they figured they might get a small toy hauler, 18ft, and save some hotels along the way. Also thought they would take a toy along as they go to help the monotany of their time on the road. So last fall for one of their meetings, they flew to Dallas, and while there, purchased a Honda Gold Wing and drove it back to Montana. They'll put that in their little toy hauler and take it a long. Soooo...... most of the winter my friends stuff has been in my wife's ear about how much fun it is, and all of the other people we both know that have bikes that we can get out on rides with. It didn't take much convincing, I've wanted to get a bike for a long so started looking a lithe over a month ago and finally found one. So last Friday after work took off for Eastern North Dakota to go get my new to me purchase. Was a miserable trip. I was pulling a 17ft empty cargo trailer and drive in 30-45 mph head/cross wind the entire way. Pulled into my buddy's house in Bismarck at 2 am, but by the time we visited and I got settled it was 3:30 am and was up at 7:30 ready to drive the remaining 2½ hours. He had different plans so after breakfast we didn't get out of Bismarck until after 9:30. Had 40 to 45 mph wings the remaining distance. Long story sutures short, got home Sunday evening at 6 pm. More wind, rain, snow m, and ice on my way home. 1450 miles. Not sure how folks can live in that part of the country. Stopped and took pics from four directions. Absolutely nothing you see in any direction. Ended up with a 2008 1800, very nice shape only 25,000 miles. Trails don't open till mid June so will have some time to ride before atv season starts.

Nice old guy bike

Has been a bit since @Goober was here. Hopefully he's ok and just doing RLS.

Yeah, that’s a silencer I made from an 8” piece of iron pipe. I threaded the inside of ten exhaust opening and it just screws in. Here are a couple more pics of the flares.

Well interestingly enough, the lady who cleans our building said yesterday someone "went after the mayor with a gun" So perhaps we might see a return to the good old days, when politicians were somewhat held in check out of fear of an angry mob with pitchforks and torches.

these models do not have a pull cord, ele and kick start only.

So here’s what’s been keeping me busy. The town that I work in has had several decades of corrupt leadership who have stolen tremendous amounts of money from the city. What this means is they have neglected infrastructure repairs and maintenance. The current mayor’s first act in office was to give himself and his “chief of staff“ twice their former salaries, and to hire a water department manager who had no experience and no certifications qualified him for such work. With the week of snow and ice we had last week causing higher than normal usage and more leaks in an already leaky system, the water system has completely fallen apart. One of the wells is completely dry and the other three are running at 30% capacity. So the city is completely without running water at this time and has been since last Friday. They are saying 3 to 4 weeks before any water will be restored and likely six months before it’s really fixed correctly. i’ve been hauling water to work with me since I live in a neighboring town with no water issues. Me and one other guy in an office full of women, all industrial toilets which will not flush without substantial water pressure and no tanks on the back like a home toilet that can be manually filled to flush first order of business was to install two normal toilets with tanks on the back so that we can manually fill those with bottled water to flush. Keep in mind I have a medical clinic in my building, So we have to have toilets that flush. We only had two floor mount toilets in the building so those are the only ones we can replace. All of the rest are wall mount, and a wall mount toilet with a tank is about six weeks out everywhere I could find. had a couple of Porta potty‘s brought in because the Gym members were all complaining that they couldn’t exercise. It’s hard to people make people understand that drinking water isn’t the issue, there is no water to flush toilets, wash hands, or clean the building. Yesterday the other guy at work (who farms on the side in addition to being a health educator), brought in a couple of totes that hold around 300 gallons each. We started trying to figure out how we could get that pumped into the buildings pipes. shut the water off at the meter going to the city lines, had to step down from a 2 inch fitting on the tote to a 1 inch line going into the pump, then the outlet from the pump had to have a check valve in it to keep backflow from happening, then to a garden hose which we first attempted to hook up to the outside faucet on the building. That had a backflow preventer as well so that didn’t work. We ended up going Into the cold water supply line for the kitchen sink. Clamped a shark bite onto the copper line and added a couple of adapters where we could hook up a garden hose. we now have running water again. We will have to be frequently refilling these totes, but at least we can flush our toilets at work again. National Guard has a 2000 gallon water buffalo running back-and-forth to a nearby city so they will refill our totes. We have to pull the trailer a couple of miles down the road where the National Guard is set up. was a frustrating day with 20 trips to the hardware store trying to find different adapters to make sure that we had everything like it should be, but feels good going home knowing that we at least have a temporary solution