shadetree

is that the gallows ??..lol.

then the wheel cylinders are seized up on right side. remove the brake drum, work the lever, does the brake shoes move then ?, if not ?, then the wheel cylinders are seized , there is a trick to get them out, takes a grease gun, and a zerk grease fitting, screw the zerk into the cylinder , either hole it will fit in ?, use a metric bolt if you need to stop up the other hole ?, or leave the bleeder valve in it if you can ?, use the grease gun to press the piston out of the wheel cylinder, i do this all the time wheel over hauling drum brakes that have never been serviced. also, make sure the tiny return hole in the ,master cylinder is not stopped up ?, you can use a single wire from a wire brush to poke down through the hole to clear it.

trx400's do not have a kick starter ?!..lol. they have a pull starter..yeah yeah..i'm giving ya heck..lol. glad ya got everything !.

would i steer you wrong on an engine build ?..lol. glad it worked out for ya bro !!. i've got a mess on my hands again with this other 450 engine, but i'll get-r-done !..lol.

that looks very nice, you gonna have the complete fender set when all said an done ?, even the pull starter cover ?.

she got it out with a very small pair of tweezers , had also build up of rust, eye is sore..but doing better. i am the same way you are..never bother finding them, go ahead..and sure enough..always get something in my eyes !..lol. i'll learn one of these days. gave me some eye drops to use, gotta go back thursday for a check-up.

@AKATV ,he'll be along to help you.

Ah yes, another trx450S project, story of my life. this is another trx450S from catfish's bone yard ( more like atv lot ?! ) i used a few parts off of it to replace the parts i needed for the '04 trx450fm/s that is now up for sale on CL's. anyway, i finally had a chance to roll this 2001 trx450S into my shop, drain the oil..or shall i say.. '' what i thought was gonna be oil '' ?, nope..water poured out of drain bolt hole for 3 min's, then finally some oil..lol. yep..you guessed it, i ripped the engine out of the frame after speaking to catfish, we both decided to tear it all apart, give it a good washing inside the cases. i needed to remove the front cover anyway, and see how bad the cam chain was ?, sure enough, it was stretched a little..not really bad ?, but bad enough i would not trust it in the long rides !, so i sat down, and ordered up some new parts from rmatv. List of new oem parts : brand new oem speedo ( they call them speedo's on the early 450's ), brand new air box, air box lid, air filter, filter stay, air box to carb boot, air filter cage ( metal part inside air filter ), air box lid clips, oem complete gasket kit, D.I.D. cam chain. i did not order oil seals this go around, i looked all these over, and they seem to look to be in great/new shape ?, will leave them in. i tried to hammer the centrifugal clutch off the crank, but this one is not letting go easy as all the rest ?, it has been off before, as i can see two nut stakes on the nut..so whoever installed it back on ?, hammered the crap out of it back then, and i can not get it to pop off to save my life, so..i finally bit the bullet, and ordered a clutch puller tool to never run across this issue again in the future. i do have a spec bolt i use to remove the flywheels, got that covered. I do not know what kinda final shape this project will turn out to be yet ?, but if anyone knows who i am building this for ?, knows money is an issue when it comes to restoring a atv for him..lol. i will try my best to make it a good atv for someone to enjoy , but i can only do so much with the parts i have on hand. NO, i do not have any pic's to post yet, i've been really busy lately, and have not had time to do much of anything. just came back from the eye doc tuesday, got rust chip in my right eye, it's healing right now, still hurts..but i'll live..YES..I KNOW I SHOULD HAVE HAD SAFETY GLASSES ON WHEN I WAS WORKING ON REMOVING THAT RUSTY HITCH FROM THIS PROJECT ?!..lol..i'm hard headed..suck it up butter cup..lol. i will update this project as i go.it wont go fast..i got too many sticks in the fire right now, one thing at a time. I have a early trx450es ( no..i am not working on the engine ! ) for a cust who needs a rear end rebuilt, i got a brand new oem rear diff from honda, left rear axle tube bearing and oil seal, axle, and rear hubs on order for him, waiting on those parts to come in, so i can put his atv back together, adjust the valves, collect my labor fee ( 275 bucks ) to do all of this. he claims to have a trx300 that needs a top end job ?, told him i'd do it for 300 bucks, we'll see how that pans out. I also have a trx420fm in the future that may or may not need an engine over haul ?, have not heard back from him yet ?, we spoke a couple months ago, he's in our deer camp, wants me to fix this atv, we'll see how this pans out soon, he said he was gonna bring it to me in april ?, time will tell. soooo, as you can see..i stay very busy..always got something going on. anyway, i'll keep this project going when i can ?, just don't expect to see new info every day !..lol.

you should tell your nephew do his home work..lol. been doing this almost 30 yrs now, i know my honda's for the most part, DO NOT RUN THEM WITHOUT A BATTERY !. and you are welcome :-).

no pressure or fluid to right side tells me the line is blocked ?, or you have air in the line ?. most times..if you can not get lever pressure ?, it tells me air is in the line/lines !. i've done a tone of brake work, on some where ppl worked it for weeks/months..and could not get the brakes working ?, well...my system works 100% of the time i do brakes, has never let me down yet.

yes, it will start, and run without a battery, BUT IT IS NOT A VERY GOOD IDEA !!, you will burn out the c.d.i or the stator, or the reg/rec, ALWAYS HAVE A GOOD CHARGED BATTERY IN THEM !.

bad c.d.i. replace with a new c.d.i. from honda. THE 1988 IS A ONE YEAR ONLY C.D.I. !!!, do not waste money on china crap that claim all c.d.i.s are the same !.

if you went through all wheel cylinders to make sure you have them free'ed up ?, then next make sure the adjuster star wheels are not seized ?, one side of these left hand threads, other is right hand threads. once all this is working , adjust the brake shoes all the way out until the drum barely catches, then back the star wheels off a click or two. then use the vise grips near the master brake cylinder, pinch off the line enough to build pressure on lever, slowly ease off the vise grips just enough to let the brake fluid pressure from the lever flow through the line, when lever is built up enough, then open bleeder valve at left front side, close bleeder valve, let go of brake lever, rinse and repeat until you no longer need the vise grips on the brake line.

if this shift drum is for the trx300fw ?, the trick is to install the outer brackets that hold the bearing in, two dowls, metal plate i think it is ?, this keeps the shift drum in until you work that left side.

your first mistake ?, wasting money on a '' new performance air filter '' wasted money, stay oem from honda make sure oil you get for the engine is wet clutch approved !..DO NOT USE CAR OIL IN THE ENGINE !. use 80w-90 gear oil in the front and rear diff's if its 4wd ?, if 2wd ?, then just the rear diff. most 420's are disk brake up front, drum in the rear, be sure to inspect or replace the pads and shoes if needed ?. if this atv has a snorkel ?, chances are its been in water..and maybe even sunk ?, there is no cure for a sunk engine unless you split the motor, clean it all out, replace any bad bearings while in there. i also would plan on replacing the cam chain with a REAL d.i.d cam chain, yes..there are fakes out there !. anytime you take a used atv under your wing ?, ALWAYS PLAN ON DOING A TON OF REPAIRS TO IT !!. never ..EVER..ASUME IT'S TURN KEY..LOL.

where are ya located ?, near north little rock, ar ?, i'll fix ya up on a backing plate. but from what i have discovered last night, the trx350 rancher is the same backing plate used on 400, 450, and 500 from what i've seen and tested.

yw. i just gotta ask ( i'm good at it..lol ) you are going through all this trouble to make the frame, swing arm, a-arms, hubs all painted , but why isn't the engine painted all shinny ??..lol.

word from the wise, when you walk away from this kinda work...come back days..weeks...maybe even months ?, you WILL forget where you left off !..lol. always take pics BEFORE you remove a part if you are new at this ??. that cable , bend end, mounts tang side down to the spot at right rear top side of engine, 10mm headed bolt. flat eye attaches to the right frame where all the connectors slide on the tangs. other end attaches to the battery neg post. from battery, red end of harness goes to battery on pos post, then the other end attaches to the starter solenoid, the other side of the starter solenoid post runs to the starter. NEVER WIRE THESE BACKWARDS !.

if you use a new gasket, and it still leaks oil ?, then this is a mechanic issue..not words of wisdom issue..lol. this is a center case gasket, NEVER CHEAP OUT ON THIS GASKET IF IT CALLS FOR IT ?!!. all other gaskets ?, not a big deal..easy to replace, where is the center case gasket..its not easy to replace...YOU SHOULD KNOW THIS !!...LOL. i thought i taught ya well ?, but i guess you fell asleep at the wheel during that class session..lol. anyway..thank you for doing it the correct way bro !!.

very wise move grass hopper !!. please do not take short cuts...this is one area you never skimp on.

well...at least they were smart enough to put a spare tire on it !!..lol.

okkkk..don't blame me when you see it leaks oil later on..lol. i do not trust 20 something yr old gaskets, spec when they are split ?!. i always...ALWAYS ..replace main gaskets on center cases..that is the last place you want an oil leak !. outer ends ?, not so much work..center ?..yikes !..lol.

correct..but even straight cut gear teeth wear..i always replace them as a set..when you are that deep into it ?, do it once..be done with it.

looks like you did not add the oil pickup screen eh ?..lol. i know..i know..it was not in there to start with..least you were not like me..and forgot to put it back in ( yes..i went and split the cases back apart, and installed it back in..lol ). sure hope you used a new gasket...and scrapped off all that old gasket clean ?. if you did not ?, it will leak oil.

you can use a dremel to widen the lower hole to get to the washer, but by doing this..you must rinse the cases out very well from all the alum shavings. as for which side to lay the 300 engine down when splitting the cases ?, left side goes down, ( stator side ). always have the centrifugal clutch facing at the very top. new engines like the 350 rancher, 400, 420. 450. 500..all of these must have the front clutch cover at the top, stator side ( rear ) on the bottom. yer welcome..lol.