SittyDown

Very nice!! Do you mind me asking what kind of D-rings you are using to attach those turnbuckles to the racks? That’s pretty slick...

That’s good advice, I forgot about moth balls! Thanks again!

Thank you! I have looked this thing over a bunch and have been surprised to find all the connections clean and dry, and not a single chewed wire on the machine! Like you, I see signs that mice have been around, but I’ll be damned if I’ve seen one or any damage they’ve done. Pretty much exactly like my deer season this year 😂

That’s really not too bad though, to get you closer to some camo...I kinda like it!

Got the cover and stator assembly removed...it is possible to do it without removing the swing arm, but you have to remove the starter and hold the reduction gears clear of the cover to wiggle it around and remove it! I was surprised when I ran into oil behind that cover (started to get worried, but did some reading and found out that’s the way it is supposed to operate) but won’t be able to put it back together until I can get a new seal, and a new o ring for the cover. Probably should have planned ahead a little better, but here I am. 😂 Is it ok to use Ultra Black for the grommet where the wiring passes through that cover, or does it need to be Honda Bond? The ignition pulse generator screws had red loctite on them, so I’ll go back with that as well. Thanks again! Also, it may just be me, but the old pulse generator looks a little swollen, and the magnetic part looks pretty worn.

Great info there, going to try to replace the pulse generator tonight and report back tomorrow. Thanks for the reply I appreciate it!

That’s what I figured, thanks for the reply! I’ll keep everyone posted on the repair...

I’m dealing with a similar issue on my 04 Rubicon 500...following this post and will update my own as well!

Here’s another good choice, most Napa stores keep this and they can all order it. Valvoline 817263 It says it’s suitable for wet clutch applications 🤷🏻‍♂️

Hey all, I’ve got an 04 Rubicon 500 with intermittent spark. I’ve been running in circles because of it being intermittent, but now that I put some time into watching the spark (and verifying fuel and compression) I’m fairly confident that’s my issue. I’ve been using the service manual download and the ignition pulse generator assembly is failing the test. Everything else checks out (Connections, fuses, ignition coil, ECM) so I’m going to order one Monday. Has anyone changed one? I know it’s inside the alternator cover beside the stator...but the manual says you have to remove the swing arm to access it. I have the air box removed, and it looks like there may be room without removing swing arm?

AKATV I actually sent you a PM! 😊

Wow thanks everyone!! 😊

New member here from Southern Indiana. I have a new to me 04 Honda Rubicon TRX500FGA. It’s got a Harbor Freight winch that works just fine, front disc conversion, and a Moose snow plow. Trying to work through a couple issues brought me here, and the manual downloads have been a great resource, thank you!

AKATV could you PM me? I have a circuit board needing repaired! Thank you!