Orville538

 Hello guys,I haven't been in this site for a while, I had some help for my 300ex here a few months back, but its gone now,now I just finished the build on the 700xx and the first time I turned it on it started right away, rode it but had other things to address but I just wanted to try it,now second ride,I had it all set,it startted right away, I don't know if I should of let it warm up a bit,but after 1 minute I took it for a quick ride and coming back home when I pulled the clutch in it just shut off,and I tried starting it but nothing, so I pushed it home and checked for spark,it gave me a ! of a shock!!!!  the spark plug I had was a ZFR7F-6 and it was black, so I put in The correct one ZFR7F-11 but it didn't start,but it did have a little bit of ticking....so valve need adjustment for sure....

Yes Sir I will post pictures of the rebuild.... I've bought many new parts for this atv ...I think the guy that traded me this atv wasn't quite honest...but I have managed to get it back in shape...slowly but surely...I need to buy a piston which I am debating on which brand... CP CARILLO/Wiseco/Vertex/JE ???? And I need a set of rear tires as well to finish up the build....

Thanks for the info I really do appreciate it,finally I have gotten around to finish the Trx700xx because I was building a Raptor660r with big bore and all sorts of racing parts,and it was quite the ride....very expensive experience!!!! Lol.... and now is the 700xx turn to get back out there where it belongs!!!! Because this thing(The 700xx) would've gotten parted out if it were to end up in someone else's hands....I bought an almost new wire harness for a very very cheap price!!!! I also bought both rear knuckles,rebuilt both the rear cv joints,split the cases and cleaned up everything inside of it....got an entire brake system,caliper with brake pads,rearmaster cylinder and rear brake pedal...I mean the entire assembly.... all I did was installed it....

I recently purchased rear rims for my 08 Honda TXR700XX and it was from Ebay the seller is atvgalaxy now the size of the rims are 10×7×10" here is a picture  DWT REAR WHEELS   what size tire do I need? And is this a mistake by them are these front wheels?  They had me wait 3 months for this rims,because Honda TXR700XX uses special rims....

4 minutes ago, shadetree said:

not to toot my own horn here ?..but i sure get a kick outta seeing members fussing over feeler gauges !..lol. ( no Orville538, i do not use them ).

Ok,good for you sir!!! I mean some people have the giving/blessing of knowing to do some stuff by feel or by eye.... but since I'm learning alot of this stuff I guess asking the people who have the knowledge would get me where I want to be,and there's alot of money invested in the atv....I don't want to be braking /bending  valves or hotcams,messing up my new wiseco piston, but hey Man I'm not being sarcastic or anything like that...but good for you.... I ask for help because I needed it.... and I appreciate anyone taking their time to help me out!!!! 

1 minute ago, toodeep said:

My feelers give both inch and mm sizes on them. Looks like the conversation is jumping back and forth between the 2. If that card said .10mm that would be the .004 inch. Just making sure it's clear since I seen that .0015 thrown out there. 

I have the same feelers as well, ok so if 10mm = .004" then .15mm =?  'ppreciate the help,thanks...

28 minutes ago, SlammedRanger said:

I wanna say its .005 for both on a 300ex. My 400ex is .004 intake. .005 exhaust. Let me do alittle quick research.

 

Yours are set same as the 400ex. 

.004 intake

.005 exhaust

Thank you very much both you guys,Fish & Slammed  I really do appreciate the help,I saw something similiar to this setting,the .004 In & .005 ex but I was a little skeptical about it.... but now you say the same so I guess I will do it either tomorrow after work..... Thank You!!!!!

On 3/13/2020 at 8:36 AM, SlammedRanger said:

Yep i see 2 options. Split the cases. Or find a good bottom end somewhere. You are gunna find more problems with that bottom end for sure bud. I would 100% be changing the oil pump either way also. Just from experiance of having an oil pump fail on a 300ex while i was riding it when i was 16. That was actually the first atv engine i ever split. It wiped the topend out. Cam and rockers. And ruined the crank aswell. All in a matter of a few minutes ride. Gotta do it right the first time my man. 

 

On a side note. CP custom pistons take a month to see it. I know this from experiance aswell. Being that my custom stroker 440 is running one. And i had to have 2 made because of a mistake on hotrods part. Be sure and measure everything also. CP didnt do anything wrong for me. But trust no one!

Ok so I got the 300ex running,split cases,took out the entire dark piston ring in pieces and some shrapnel not much,now long story short,it crank right up!!!!! Now here it goes,but there's a little bit of a knock thats bothering me,I have a stage 1 hotcams, Blackdiamond kibblewhite valves, wiseco timing chain, now the hot cams came with card for valve lash,10mm intake and 15mm exhaust, my valve gauges say .015mm and .010mm another one says .0015,which one do I use,I mean I adjusted the valves with the .015 & .010 and it fired right up I even rode it lime I stole it for 30 minutes nonstop and did an oil change,and that's when I heard a little louder knocking, not as loud as before but not as it was at first that all I heard was a tick tick... any suggestions PLEASE!!!!  do I need to buy another set of gauges? Or what should I use .005 intake  and .007 exhaust?????   MAN THIS THING FIRED RIGHT UP NO ISSUES!!!!! I WAS SMILING!!!!!

7 hours ago, SlammedRanger said:

Im gunna go out on a limb and say you saved this quad from the scrap heap! I can do nothing but shake my head when i see things like this. That poor quad. It didnt do anything to deserve all this.

Dude!!! No bs I think the same  I'm like why ? Why treat something this nice like scrap?since I was a kid I always wanted one,and always asked myself why some people who have ATV's just wreck them and let them go to scrap? But I will do my best to restore it little by little... here in Florida I've seen some crazy work on quads....and I mean hacked up work...no atv deserves to end up like this unless it's totalled from a crash.... I also bought a wire harness for it too...the one on it is rigged with tape 

1 hour ago, Akunin said:

Any progress? I'd like to hear your plans or see the progress

I've already ordered, rear rims,got an OEM one but someone gave me a good price on a set but they're 10" also I bought the case splitter and case puller,and I also bought the rear hubs,the ones on it,Man look at this!!!! Also those nuts and bolts are what he used to tighten the rims that were on it,after I open up the cases then I'll go from there....but I'll keep you posted, Thanks for Asking @Akunin

6 hours ago, retro said:

Yup, gonna have to split that one too!

Thats what I was afraid of!!! Not afraid of doing it, but Man another motor to go to surgery!!!! I'm just gonna try and flush the crap out of it!!!! I know it's not the correct way of doing it,yesterday I ended up putting in new Tie rods,new rear brake and rear master cylinder, new front brake lever with the master cylinder,new Blackdiamond intake & exhaust Valves,and I now I have to wait longer for the wiseco timing chain because the post office delivery lost it,so it was refunded, but I bought another one,so I still have to put together the Hotcams with new sprocket, and wait for the timing chain guides, oil filters, (bought a case of them) & timing chain that is all coming this coming week!!!!  Also waiting for my Piston from CP Carillo for my Yamaha Raptor660r,custom made piston,and  the last of the Ferrea Valves..... and I have to start on the 700xx soon also....I got my hands full!!!! But one at a time!!!! See you soon!!!! I may just open this cases too!!!! I don't like half ! work, My Dad said to me,"Son if you're going to do something, do it Right,or don't do it at all" "Let someone else do it" 🤔🥴🛵🔧🔩🛠🧰🗜

Hey guys,how's everyone doing!!!! Thank you all for the great help you've been,so I got majority of the parts,I'm just waiting for new oil filters and timing chain guides, the ones on the 300ex were done,so anyway I opened up to install a new clutch and look what I found!!!! Wow!!! Even a couple of o-rings too!!! Wtf!!!! But I'm going through everything, I just don't want to open this cases either...I already have to do the 700xx and I'm dreading it!!!! But I will share the build of the 300ex,I have everything, well mostly everything but the parts that are coming this  Monday  and Tuesday ..... see you soon!!!!

On 2/13/2020 at 7:10 PM, Akunin said:

Nice! Got your bases covered, smart!

Yeah have to do it like that because to many atvs stolen.... anyway I opened the engine heads and this is what I found....is this cylinder salvageable? Also one valve broke exhaust valve,and I emptied the rest of the oil from the crankcase and I saw the valve and peices of the piston on the bottom I was thinking about taking off the engine and flipping it up side down and shaking it maybe hose off all crap out of there or is there a better way? Because that would be splitting cases correct? Slammed/Fish/anyone else that could help out please!!!! I knew there was something wrong with it but not this!!!! 😱🙈🙉🙊🧐

31 minutes ago, Akunin said:

M-Quick knows these things inside and out so hopefully he pops on here or possibly PM him. 

 

For me personally though I would have jumped on that trade. I'm very impressed with the xx and I consider it the best quad I've ever owned. Looks like its had its share of upgrades and it looks to be in overall good shape.. my only concern would be .. did you get a clean title or a bill of sale with verified identification? With trades I'm always leery about them. Being stolen. But if that's good to go I say.. ! good trade!

 

If your use to riding a solid rear this thing will surprise you in the corners. It hooks like none other so be prepared if your expecting to spin cookies or whip the back end like a raptor. The independent rear grabs and wants to go straight. If it's a concern look into getting a different sway bar. Independent rears are amazing in rough terrain. 

 

That said if you into jumping this again is another difference from a solid rear.. you can come off a jump and land on one wheel with the IRS vs never wanting to on a solid rear. 

 

Just a few things off the top of my head but it's a Honda and lives up to its reputation.  Tear into those rings and enjoy it!!

Akunin yes the guy is an Appliance store owner and his son is a state trooper so the vin is clean and I have a bill of sale....

Just now, toodeep said:

Depending on what the XX needs you probably got a good deal. The 700xx was only produced for 2 years so they are not that common. @Akunin has one and can give the goods and bads about them better than me (I haven't even rode one yet).

 

Kymco is a Taiwan company isn't it? An old company but newish in the states. 

Yes Taiwan you're right!!!!

7 minutes ago, SlammedRanger said:

Thats a really good deal! Chinese quad for a japanese quad. Or atleast i think kymco is chinese?

Believe or not is Japanese Kymco and Polaris are same maker!!! Look it up!!!!

Today someone traded me this 700XX  for this Kymco 300.... I will need to do some work as far as the guy told me.... is fuel injected motor and Supposedly a rare bike!!! IDK You guys help me out here.... maybe I made a mistake?  Or did I get something nice? I fear is the piston low compression as that indicates bad rings!!!!

On 1/30/2020 at 2:50 PM, TRX Student said:

Its likely the impulse line. If the fuel lines needed replacing chances are the impulse line too, I've worked on acouple crap poulan saws that I find at the dump. Same problem every time. Old cracked fuel and impulse lines.

Also just in case anyone hasn't mentioned it sometimes the muffler spark arrestor gets gummed up with carbon crap and doesn't let the saw flow air out the exhaust correctly.... seen it happen before.... but if you got it running again,Good!!!! I've had my share with chainsaws!!!! Also if the diaphragm is kinda hard where the little round metal thingy is then chances are is not good.... good luck!!!!

19 hours ago, SlammedRanger said:

Cometic is what i always run. Never had one leak or a headgasket issue out of one. Oem honda are fine also. As long as the head gasket is a mls(multi layer steel) one your good to go. There are alot of the ones that are a cardboard like material with a metal ring around the cylinder. Seen many of those fail!

Ok I will go with that.... thank you again!!! Now this is the exhaust I bought today for $100 of someone from Marketplace ,now I need to get the valve spring kit and piston with rings and gaskets,and the Nerf bars too....

On 1/26/2020 at 5:35 PM, retro said:

If the wrist pin bore looks good, no galling, you can slide a wrist pin into the top of the rod just far enough that the pin is barely sticking out of the opposite side of the rod. Then lift straight up and down holding the long end of the wrist pin in your hand. Any play there should be barely perceptible, or none at all. The wrist pin should fit the rod bore perfectly and rotate freely inside the bore.

 

You can check the big end rod bearing using the wrist pin to lift and drop vertically as well. There should be no perceptible play on the big end. End play on the big end might measure between .016" to .025" which is probably within spec. You can look in the manual to find the service limit spec for rod end play.

 

Since this motor was such an amateur hack job (cylinder wedged into the cases) when you got it you may want to try to verify that the rod did not get bent due to the cylinder being wedged into the crankcase off-center, or unsquare with the block. You can get a pretty good idea whether the rod is bent or not by putting the new piston and wrist pin on the rod without the piston rings installed. Just slide the wrist pin in (don't put circlips in yet), center it in the piston then drop the new cylinder (lightly oiled) over the piston onto the base gasket.squarely. Then rotate the crank by hand until the piston is near TDC and rock the piston in the bore by pressing down on the piston over top of each end of the wrist pin. The piston should be free inside the cylinder while rocking it.

I will check on all this tomorrow,take some pictures and let you guys know the scoop,so far on parts,I've bought new Valves Kibblewhite Black Diamonds,Hotcams Stage 1,Rockers arms,Camshaft sprocket,74mm Cylinder  and FMF 4.1 exhaust,.....Now  next week I'm planning on getting the Kibblewhite Spring Valve kit, New Timing chain and 74mm Wiseco piston kit,what are the best Gaskets and Head gasket to use?  Thanks all you guys for taking a little bit of YOUR time to help me out get this atv right for my son.... 

1 hour ago, retro said:

@Orville538, have you checked the top of the rod for wear yet? Is the crankshaft and rod in good condition, bottom end in good shape?

R

@retro honestly no I have not checked the top of the rod,what would I be checking for? The inside where the piston pin inserts through?  Because like I had previously asked Slammed or Fish I believe that the rod has a little play from side to side but no play up and down,but I will double check again just to be sure since all this is exposed now,because once this is all put back together it would suck opening up all of it again...thanks for the letting me know retro!!!!

On 1/24/2020 at 6:06 PM, SlammedRanger said:

Go fmf. Or hmf. DG is cheap but you get what you pay for. DG always sounds raspy and doesnt really gain anything but sound really.

Ok...thank you very much Slammed....you've been a great help and  Fish as well.... so far I have new Rocker arms (Honda) New Camshaft sprocket (Honda) and Hotcams stage 👈this I have  and next Im ordering the Valve spring kit with KibbleWhite Black Diamond valves,Cylinder kit with Wiseco piston and the FMF exhaust and Id like to grab a Dyno jet kit too!!!! Thanks 

1 minute ago, Orville538 said:

Jeepwm69 yeah I guess someone tried that grinding thing you're describing,but this 300ex had the loudest knock ever....and I thought that the cases were machined to fit that bbk but when I had difficulties pulling up the cylinder I knew something was wrong,then I noticed the grinding and was like wow...No F'ing wonder this thing is knocking...but anyway I'm buying parts as I can,but everything I'm buying is Wiseco,Hotcams stage 1,Kibblewhite racing spring kit and kibblewhite black diamond valves(something like this),Honda rocker arms,Wiseco Timing chain ,and debating on the exhaust.... FMF or DG? ,I will post pictures when I start to rebuild it again!!! Then I have to finish my other one... Raptor660r but that's gonna be a BEAST!!! 

3 hours ago, jeepwm69 said:

I don't know squat about the sport machines, but supposedly the 520CC top ends will fit on the 420 ranchers and 12-up 500 Foremans if you grind the cylinder down to fit in the cases.

 

After looking at what had to be done to get that one to fit, don't think that's something I want to do!  LOL

 

I'm going to follow this one.  Post lots of pics while you put it back together please!

Jeepwm69 yeah I guess someone tried that grinding thing you're describing,but this 300ex had the loudest knock ever....and I thought that the cases were machined to fit that bbk but when I had difficulties pulling up the cylinder I knew something was wrong,then I noticed the grinding and was like wow...No F'ing wonder this thing is knocking...but anyway I'm buying parts as I can,but everything I'm buying is Wiseco,Hotcams stage 1,Kibblewhite racing spring kit and kibblewhite black diamond valves(something like this),Honda rocker arms,Wiseco Timing chain ,and debating on the exhaust.... FMF or DG

11 minutes ago, SlammedRanger said:

Can you take a picture of the whole quad? We want to be 100% sure you have a 300ex. Im not sure where you are getting trx ex300 from? That isnt anywhere or on anything. From the pictures you had posted before im almost positive its a 300ex sport quad. If it is we can leave your thread in the sport quad section. If not it should be in the utility section. Just to keep things in order.

Also I'm gonna get new plastics from someone  for a decent price,or I might just get the front plastics and gas tank cover.... but Sir this is where I'm getting this Trx EX300 from... its an 04 TRX EX300