jeepwm69

Well I've only tried to fix the PS light/ not working on one machine, and didn't have any luck. @toodeep probably has the most experience with them. If you look in the service manual there are troubleshooting directions, but following those I was unable to find a problem with the 2010 420FPA I was working on at the time. What specific 2008 model do you have?

Well you can use any year harness BUT you have to have the proper accessories for the given year. For example, if you have a CDI on that machine, you'll need a first gen harness (88-92) to work with that first gen CDI and regulator (also called a rectifier) If you don't have a CDI, and will have to purchase one, then you just need a harness with matching CDI. The starter solenoids etc are all the same from 88-00. You just need the harness to match the CDI and rectifier. There are 3 "generations" of Honda 300's 1st gen is 88-92 2nd gen is 93-97 3rd gen is 98-00

If I have to. I don't like it.

Based on what I see so far, your best bet would be to order an entire used harness from ebay or Powersportsnation.

If the new one gives you any problems get a good one, OEM or Shindy are GTG

You're not using cheap ebay/amazon bearing are you? Shindy or OEM only.

I'd send Honda of America that link you copied above. See if they want to ignore that again. When word starts floating around the net about a problem, it should force their hand. Keep us posted!

Most likely the shift linkage is slightly off, and when the machine flexes it's pulling the shifter out of gear. Make sure the upper and lower motor mounts are good, and I'd look and see which way it's moving out of gear, and slightly adjust the shift linkage the other way. It's just a bar with threads on either end, so you just loosen the nuts and turn the rod to adjust.

This one is a Rubicon/ Hondamatic.

You sure are crotchety. I agree with you, and feel the same way. Does that mean I'm crotchety too?

Ah, so it's the ring gear rattling against the pinion gear? That's not a terrible job, especially given the straight cut gears these have. It still SUCKS that Honda isn't taking care of it though! From what I've seen/read/heard, dealers hate warranty work. They don't make much of anything on it, and it ties up their mechanics. I'd still think the place that sold you the wheeler would want to do it as a good will gesture, but I guess not. I'm sorry you got a lemon. I have a 4 year old, 19 year old, and 20 year old (all girls). When the older girls were young I was a single dad. Wrench time (and funds) were limited for sure. When the kids got a little older I had more time to wrench, and then I decided I hated having free time so I had another kid🤡 Anyhow, if you want to tackle this yourself, it's just unbolting parts, taking things apart, putting it back together with a new shim in there. If you want to tackle it yourself, we can walk you through it. Won't be anything difficult, just unbolting and re bolting stuff together. You'd need a pinon gear socket, but a piece of square tubing seems to work for most people. Again, sucks that you're having to work on a new Honda already. I'd be noisey to Honda corporate, send them what you posted above from the other forum. I think Honda is still at the top of the food chain as far as reliability goes, but they are no longer head and shoulders above the competition like they used to be. I've gotten away from newer Honda stuff, but I have a LOT of older Honda vehicles, ATV's, and various small engines. They used to be better. Sucks, but that's what it is. If you need advice on the job, let us know. If you have someone else do the job, have them take pics and document what they find here please. It will likely help others with the same issue. Might even force Honda into a recall situation, which is really what should happen.

@AKATV is the meter guru. He might be able to assist on the meter readings.

Welcome aboard. The engine uses the speed sensor for shifting, so without it, the thing's not going to run right. If you look in the toolbar at the top of the page, there's a "service manuals" tab. Click it and download the factory service manual for your machine. It has some pretty detailed troubleshooting in it. Is your meter throwing an error code, or just registering 0 all of the time?

Says the guy who only likes Japanese stuff. LOL

If people weren't looking closely, put them on a Foreman and show them 85 on the speedo. LOL Insert "countries that use the metric system" and "countries that have put men on the moon" meme here. My wife is a science teacher. She frowns upon non-metric units of measurement, for what it's worth.

Type the @ sign, followed by the member name @AKATV it looks like @ESG needs meter work.

Have you tried calling Honda of America? Get a live person on the phone rather than an auto reply. Ask for a supervisor. Tell them the dealership told you to "run it till it breaks" If you're the social media type, tag the dealer and their response to your problem. Set up in front of their shop on a saturday morning with a big sign that says "My brand new 2024 Honda that I purchased here has something wrong wiith it and this dealership won't even look into it". Again, you shouldn't HAVE to do all this, but I'd sure do it on principle. You might try calling the next closest dealership and tell them what's going on, see what they say.

If they can hear the noise, I would ask them if it's normal. When they say "no" then I would say "something is obviously wrong or it wouldn't be making that noise.... I hate to say it, but you might have to just make noise and get progressively louder until someone addresses your issue. Sad that it's that way. It will be a PITA to get them to address it, and you could just always learn to live with it, but were it me, I'd make them miserable until I got resolution. We all know it shouldn't be making that noise, and with 80 miles on it they should be taking care of it.

Man that thing is mint. I can't believe you haven't sold it yet. Have you had it listed on facebook long? As much as I hate it, that seems to be where all the buying/selling action is these days.

So it that one for a Foreman/footshift or for a Rubicon/Auto?

Thanks @retro! Luckily I have my kid's 05 here in perfect running condition, so I can use hers for testing. She's leaving for camp Thursday (counselor) so she won't be needing it for a few weeks.

Great write up @retro. You tend to take more time and do things "right". I just slapped in some new bearings, bolted them on, and went!

WOW

AHA! Found it. @shadetree was spot on about that washer that says "out side" on it. #25 in the clutch schematic https://www.partzilla.com/catalog/honda/atv/1985/trx125-a-fourtrax-125/clutch

Brother in law picked up an 05 350 ES and brought it to me. It's yellow ( @shadetree!), diffs and engine aren't mud stained, but looks like it's been sitting out in the sun. Had to put a battery on it, old one was so dead it wouldn't even click a tender on when I hooked it up. Meter was completely toast. Water intrusion. I think @AKATV is going to be able to piece one together for me. Market rate on them now is about $300 since they're discontinued and getting harder and harder to find. PSN had one for $289 that I started watching on ebay, and it sold in about 24 hours (to someone else, not me). BIL said he wanted a working meter, so he'll have to cough up the going rate for one. Other issue is, no spark. He put a new OEM voltage regulator on it based on that fixing a 450 Foreman he brought me last year. No dice. I put a 3rd gen 300 CDI on it yesterday just to see if that might be the problem. Still no spark. So the easy "parts swapping" is done. Looks like I'm going to have to get out the meter and start doing things the hard (proper) way. With no meter I can't tell if it's throwing any codes, but I did get it into neutral so it will at least spin over now. Going to check spark plug first, then start on the other ignition components. I have my kid's running/driving 350 Rancher of the same year, so at least I have extry parts for testing purposes.