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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.

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

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

To anyone who is considering sending their Speedo display to AKATV for repairs just do it! I just received back my Rancher display and it looks brand new! Quick turnaround, very cordial, and very professional service!

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

Today, I moved my atv from the back of my garage to the front of my garage in anticipating of a camping trip this next weekend.

@sshinnssi - AKATV did a great job on mine - it will cost ya a couple hundred plus but still cheaper than replacement unit which they don't make anymore. Before and after

I rode mine a couple days ago. Stayed at my buddy's hunting shack. Two guys rode in his Can-Am Commander and I rode my Rubicon. Rode through the woods to tour one of the last remaining CCC camps. Then continued our loop back to the shack. 51 miles total. Saw a bunch of whitetail deer and ruffed grouse along with the usual eagles. Beautiful 50 degree day.

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.

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.....

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.