shadetree

if you are calling the CKP the same as the pick up coil ?, i just looked your model/year/make up, i see honda in their wisdom decided to make the stator and pick up coil all one part ?!. and its not cheap...right at 500 bucks. you can find this info under the fich parts under generator, it is the stator that has the pick up coil.

keep in mind, the trx400fm has the same rear diff as the trx450fm. check with power sports nation for a used rear diff before you buy a china rear diff !.

are you sure you unplugged the gear switch ?.

sounds like the gear position switch is bad ?.

@AKATV

i would start with a clutch adjustment.

it's china junk, don't bother !. honda hates china parts.

i normally just buy the ring gear and pinion gear if its still being sold from honda.

as akatv ^^^ posted, yeah..those spacers on the ring gear are very easy to miss/over look !. most times in my work, they either stick to the ring gear ?, or stick to the bearings ?..most on ring gears. as for which ones you will need ?, well..this is an open and close case !. all depends on how much wear you have on the pinion gear and ring gear teeth ?. i normally just re-use the spacer washers that are on the differentials as i put them back together. if i have to buy new spacers ?, i just buy stock size, but i always have these spacers when i tear them down. '' if '' i tear one down, and someone '' miss-placed '' them ?..lol. i will round up some spares i keep on hand, do a dry fit. by this, i put the spacers on the ring gear, put it together, spin the pinion gear by hand, rocking it back and forth, i can feel/tell how much space i have before the two teeth hit each other ?, if i feel too much slack before the teeth '' hit '' ?, then i need to locate a thinner spacer washer...this is how i do it. yes.the book says to use a spec tool to '' dial '' in the back lash ( same thing as teeth space ) ?, but i go by feel.

i have not seen mac around for some time.

ok..i looked at the micro fish...going by it, you have the shift forks installed right.

top pic, i'm looking at the shift fork, and the gears the way they are lining up, something is off, its like the shift fork in installed upside down ?, the reason i say this is, because the gear teeth are not lining up, nor are they sitting even across the gears ?. makes me think the top shift fork is installed upside down ?.

if you are in the states ?, send me a pm with yer cell #, i'd like to ask and go over a few things with this tear down. DO NOT POST CELL NUMBER OUT IN OPEN !.

a couple tips : MAKE SURE YOUR SHIFT FORKS ARE FACING THE CORRECT WAY WHEN INSTALLED ?. each shift fork has a letter stamped on it, bottom to top: RR, C, FF. meaning, the bottom shift fork will be the rear, c is for center, f is for front/.forward. each shift fork MUST have these letters facing up as you place them in the shift drum !. second tip: when placing shift drum into bottom case, its a good idea to have each grooves end line up from top to bottom, this is the stop end for each shift fork. it does not matter where you have the shift drum sitting once you place the shift forks in the case, and go to install the shift forks ?, but it does make it alot easier to line the shift forks up while placing the forks into the gears slots/grooves when doing so.

ahh..yeah...not sure about the bolt pattern on the axle tube to brake backing plate ?. i '' think '' they are the same ?, let us know !.

keep us updated !.

the bolt pattern is the same as most all of honda's today. think about this for a min: i used 2003 honda foreman 12 inch rims on a 1989 trx350D front end so i could use the high lifter brake kit, sooooooo...bottom line...the bolt pattern is the same from 1989 to 2003.

have a look at the choke enrichment valve, and choke cable. the enrichment valve may be stuck in the carb, and not re-seating back down like it should.

you could have went to D&B electrical and got a great starter for 1/3 the cost..but oh well..your money..lol.

check on ebay for the air filter element, you can still buy them new, but be warned, they are not cheap !. they are pretty hard to come by used, i had one, but used it on my last 450 build. even the air box itself is discontinued, so do not damage yours !. as for the drain screw, sand down the tip at the correct angle, then use a o-ring on the end of it like it should have. just checked ebay for air filter element, save your time, they are asking over retail price for used !..go buy a new one from rocky mountain atv, for $ 79.30 for brand new !, and free shipping.

i can answer this...no..it will not work. why ?, the rims on the trx350D foreman are 11 inch rims, and also deep dished, i highly doubt the rims will clear the brake kit. now..you can go to 12 inch foreman rims ( 450 foreman ), and make it work. i converted my front brakes on my '89 trx350D foreman to high lifter disk brakes, but i had to make some special brackets to fit the brake kit on it. and i also used 12 inch rims for a 450 foreman both front and rear. i had to re-adjust the foot guards to make room for the 12 inch itp mudlites, was easy though.

sxs are not talked about alot here, most here have atv's. sxs's are a whole diff world when it comes to tires.

@jeepwm69 can take care of ya :-).

haha..i am about 5 min's away from that dealership, conway is not far from me at all. been there a few times for stuff.

i try not to get into tire selection here on the forums, why ?..because everyone has their tire they like. myself..i run nothing but stock sizes for my toys, or builds ?. just a heads up: if you go to 14's ?, be ready to spend lots of cash keeping this atv rolling right !. large tires, rims..do damage to the drive line fast !. you have been warned !!. i run ITP at's mudlites on my 450, and it will go through anything i drive through, and i do not go in deep mud..or lakes !..lol.