TRX Student

I have a parts 450es with a plug and rectifier (I already robbed the stator) that I will use to sort out to get rid of the crimpage. Just can’t do it until I return to the south (southern Canada).

I’ve got a new battery on its way in the mail. When I tested the machine running today with a not fully charged booster pack the multimeter read 12.36 (which was the reading on the pack itself) and slowly descended to 12.34 while idling. I did not rev it. The crimps were already there, from PO. I had a china regulator but switched it back to the one that came with the atv, which I think is original. I’ve read enough now to stay away from China stuff when it comes to electronics.

Hey guys, on the the old forum I had started on a thread on this machine, mostly asking for help with wiring and a mysterious draw. I finished up the 300 for the most part and am now trying to finish the 450. At first I thought there was a draw on the battery, but now I’m certain it’s just not charging. Id like some help/instructions on how to test the stator and regulator/rectifier. I have the instruction manual, but don’t know how to test for continuity/resistance on my multimeter . Things I’ve done on this machine: replaced rear end with new used one, saved the tires painted wheels new carb new airfilter oil change painted parts of the frame painted racks converted the headlights to led things i need to do: figure out charging system ball joints finish lights test fan system clean up plastics plastic supports reinstall winch skidplate route brake cables and reverse cable For the record, I do have a used 450es stator on hand incase I have a bad stator.

Hurrah!

I had the same problem, didn't want to wire wheel everything, theres a really good WD 40 cleaner you can get at canadian tire, comes in a spray bottle. As for gasket material, I used a very sharp blade, and patiently went around everything. Took for ever. Ca prend la patience.

I wasn’t so lucky, the small screw broke off flush with the reservoir, I used the cap to help guide me in and catch shavings. more great info! I noticed my tie rod ends had play. Guess I’ll be switching those over too!!

I should add, because I don’t think I’ve mentioned it, Ive got aluminum big bear wheels on the front. The disc brake conversion kit calls for minimum 12 inch wheels. These work. The aluminum needs a shine, but in its current state it matches the tan plastics perfectly. Ha.

I just swapped a Yamaha big bear 350 master cylinder onto my 300 fourtrax. Easy.

Thanks for the tip @Goober never thought of smoothing the surface of the broken bolt, duh. Made things go a lot....smoother....

Fairly certain there’s a brake master cylinder on a parts 450es I bought last year, but it’s not handy right now. This will work for now! So, if anyone is on the lookout for a master cylinder for their 300, one from a Yamaha big bear/Kodiak will work. kind of comical to see Yamaha in bold then in the background Honda lol. I cringe abit, but don’t worry Honda fans, it’s not permanent.

Success! getting better at the drilling, tapping. Giving up on ‘extracting’ I also got the brakes primed. awesome.

Getting more practice at drilling out broken bolts! This master and reservoir is off of what I think was a big bear. I took it off of a machine I found at the dump 4-5 years ago. The machines were all mangled and twisted from getting pushed around by loaders, even so, I kick myself all the time for not taking them home. Now that I’m into this hobby, I realize the value I passed up. It looks as though this is a direct fit, I haven’t tried the cylinder yet, just hoping. I know I have a second one that might work. Taking the opportunity to practice my drilling out/taping skills.

I also just glanced at the other threads on brakes, I see that some parts are interchangeable from other bikes. I have big bear parts and crappy chinese knock off parts. Going to see if the reservoir/master cylinder can be a direct swap/or maybe just the internals?......Will report back.

Thanks for the tips fish, I tried clamping the hose right after the master, once inawhile I got one lonely bubble, but the handle never got hard. I guess the master is bad. I always see shindy for carb rebuild kits, do they make master rebuild kits too?

When I started tearing into this machine, the brake fluid drained out, it was brown and gross. I finished installing the disc conversion kit and managed to open the master cylinder to fill the system with fluid and bleed it. I filled the cover with fluid and pumped the handle, but the fluid is not getting into the lines, and no bubbles are coming up, am I doing something wrong? Or is it more likely the master cylinder needs a rebuild?

I hope by now I’ve learned.

Last few days I’ve been fiddling around with wiring and plastics, mocking things up to appreciate my progress, noticing something and stripping down again. Did all the ball joints, washed the plastics, tried my hand at drilling out broken bolts then using a reverse thread extractor. I think I’ve been successful 1 out of the 5 times I’ve used extractors. Break them all the time. Not sure what I’m doing wrong. Wired in the front led pods to the rear tail light. I’ll get pics of that. Been working too fast, forgetting to take pics. was too lazy to go to the garage to borrow a wrench for the rear axle nuts, I used something I bet no one here has done, a c-clamp! Well, The last piece of the puzzle arrived in the mail today, the disc brake conversion kit. Time to get to work and finish up this beast!!!!!!!!!!!

Is it one of the old ones you replaced that broke?

Quick search on eBay yielded nothing. Very rare. Ill keep the plug incase though ! Will look into figuring out how I might be able to mount a big red light cage as a headlight .

So, I’m trying to find the accessories that would have plugged into it, lights? Some sort of spot light? Would an oem winch have gone to this plug?

It’s coming close to finished! i still need to clean out the gas tank, been waiting for warmer weather. Ill wait for it to be all done and bring it up to my local garage to figure out what the exhaust needs to fit in place. Right now I’m making my plan for my led light upgrade. I was told from the old forum to wire in the led’s with the brake lights. I want to also wire in a pod light, similar to the 450 foreman, and that will be wired into the headlight/high beam. As I was poking around, mocking thing a up, I noticed this plug. It looks oem, anyone know what it’s for? Accessory guys? Right hand side handlebar.

Welcome! .....'enough tools to be dangerous'😄

Don't have a pipe wrench either. BUT! The mechanic at the garage is a buddy of mine, he's cool about lending me sockets or wrenches when I need them.

Mocked up the rear plastics, and the rear axle, love the shine. I don’t have the proper wrenches to tighten the nuts, have to borrow from the local garage, so the final torquing will wait for sometime this week.

I think it’s caltric, it doesn’t fit right, they gave me 30usd back.