Honda Fourtrax bring back from the grave

[JacobSlabach]

ok.  which manual should i get?  I'm really not sure about the year or size of this atv

[Frank Angerano]

Upper right side of page drop menu. Manuals etc.  

[Frank Angerano]

What year is that bike and the size ?

Vin#

Should be on the front frame cross bar in between the wheels 

[Frank Angerano]

Not sure if this is your bike. 

[JacobSlabach]

yes thats what my head looks like

yes thats what my head looks like

[Frank Angerano]

Ok so your timing is there. Get after it.  

Tensioner is there as well. 

[JacobSlabach]

eh sorry- computer issues up there  meant to say yes that looks like the head on my bike

so thats literally exactly how i checked timing- t mark on the flywheel and marks on the cam sprocket.  I'm thinking the tensioner is shot letting it jump time or the valves are incorrectly adjusted.  btw, I was wondering how you find certain info in the service manuals?  I find it hard to find the info I'm looking for and get lost lol

[Frank Angerano]

Have you been to the download section and successfully downloaded a manual before ?  

[Frank Angerano]

Hey @JacobSlabach take a look at these two videos.  It will help you out getting familiar with that engine. The 300 and other small cc engines were pretty much built the same.     

 

[JacobSlabach]

thanks@Frank Angerano!  My motor has the dual valves (4 valves altogether) as well, dont know if that makes any difference...

[Frank Angerano]

Same premise. Just to understand the head and cam removals and more important is the valve adjustment.  Did you buy a set of feeler gauges ? 

Edited May 12, 2019 by Frank Angerano

[JacobSlabach]

yep got all the tools form the bayou and big bear

[Frank Angerano]

Good. So you have to double check timing and then adjust valves.  

[Kartmanz W]

Keeping an eye on this thread, I will love to see you get it all up and running again how it should be. I really like the Fourtraxx but couldn't afford one and ended up with a busted up Suzuki LT250 but shes well on the mend now. I have to replace the barrel next to stop her burning so much oil! maybe then I can make some money and invest in a Honda (preferably a 4x4 but not sure how much Id benefit from it as Ive never needed it with the work I do)

[JacobSlabach]

awesome, its taking a back burner for now till i get another quad fixed, but its for sale once fixed and running

[Frank Angerano]

@JacobSlabach what’s up.  Haven’t seen you on. What are you up to ? Working on anything ?

[JacobSlabach]

ok so took the head off and found that i had indeed timed the cam to the 'F' mark which is exactly one tooth ahead of the 'T' mark on the flywheel.  re timed it back to the 'T' mark and as i was putting the head back together noticed that the intake rocker arm is worn where it contacts the cam lobe.  not sure if this really matters a lot but i did check the valve clearance at tdc and intake was 004 and exhaust was 006.  Was looking fir a new gas tank as thats the next issue..  a replacement is around $200..  the one I have has paint flakes and A LOT of rust flakes in it.  was wondering about cutting it in half. cleaning and graniding the iside down and welding it back together?  looking for advice on that..  so far I haven't put any parts into this machine but I know that it needs new brake and choke cables..  had to cut the old ones out with bolt cutters just to get the bike to roll.

[Frank Angerano]

Good work kiddo.  Have you tried to fire  it up yet with the timing correction? 

[JacobSlabach]

yes and it still ticks.  i think its the worn intake rocker.  what should i do with the gas tank?

[Frank Angerano]

What’s the year ?

If that tank is in solid condition structurally then I would make up a tip for your compressor with maybe a 16 inch long piece of flexible copper  tube and pinch the tip a little for better pressure.  Angle the copper as needed to get inside.  Stick it in the tank and blow the sh** out of it. Hit all sides and the bottom and creases as best possible. Then fill it half way with boiling hot water, add Dawn kitchen dishwashing soap put the cap on and shake the tank good.   Spill it out and rinse it all out good with a hose.  Blow it out again to get the rest of the junk and water out.  Then hit it with a hair dryer on hot so all the water inside dries up and creates no rust.  Spray the inside all around with WD 40 and let it sit a day.   

I would put a quarter tank of gasoline in it put the cap on and swish it around and dump it into a clean bucket and see if you get any more flakes or dirt.  

 

[JacobSlabach]

i looked it up and i believe its a 1986 350.  would it not be easier to cut the gas tank in half, clean and sand all the rust down and weld it back together?

[Frank Angerano]

You could but it has to be done by a professional that knows what they are doing and then pressure tested etc.  might as well pay the $200 for a new one. 

[Frank Angerano]

Can you post a pic of that tank ? 

[davefrombc]

A trick  we've often  used to  clean small   tanks is to  put some pebbles or  marbles in them  and  give a good shaking to  knock  any rust, scale or other solids loose ..  Shake out the rocks and crud. and have a look.  If there's still  build  up  in there,  do  it again.  Finally  rinse it out  and thoroughly dry.  It would be a challenge to  cut  a tank  in  half to  clean  and weld it back together. Unless  you're very skilled and the tank isn't too  thin you'll  make  nothing but a useless mess out of it, A  welding shop would charge you more than the cost a  new tank  to  do they job  if you  could even  find one to take it  on.

[JacobSlabach]

heres the tank

[Frank Angerano]

I agree and like that idea as well thy @davefrombc definitely will loosen things up. 

[Shawn Hendershot]

I  Have done the Red kote to seal a 88 fourtrax 300 and even with the second coat it still is trying to leak on me. I would go with a new tank or Plastic one. 

 

[JacobSlabach]

I think im going to go with a 'new' tank.  took a closer look at the inside and this is what i saw (i cut the tank in half so that you guys could see)

so the inside of the tank is coated with some kind of thick paint that peeled off and is almost rusted through in some places.

[Frank Angerano]

That looks pretty bad. Def going to need a new one. I will keep my eyes open for one.  

[JacobSlabach]

i found one on ebay for $99 as opposed to $200+..  inside looked non-rusty too.