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By Snick
Bought the project a few weeks ago with weak and intermittent spark. I could smack the CDI box with a screwdriver and it would work fine for a few days. Now, the smack trick is not working and machine is running awful with the weak spark and will most often not fire enough to turn the engine over through combustion (cranks very good). I ordered the GY6 CDI to see if I can get it going again as these CDI boxes are way too expensive even used. battery is fully charged and charging very good.
Wondering if anyone knows how the GY6 (6-pin AC) CDI would wire to this machine. Attached is the electrical diagram. My confusion is with the green and orange wires sharing the 2-pin connector and the Blk/Red wire that runs to the magneto solo. How would I get AC power to the CDI through pin 1 on the GY6 when the CDI has two wires to the pickup-myabe just try one (orange then green) at a time?
^PINOUT:
5 6
2 4
1 3
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By Mikey69
Heres my story. Kinda long. I guess I was a late bloomer when it comes to quads. I had never ridden a quad in my life. Rode Dirt Bikes as a kid growing up. Back in Oct of '06 I found a Mustang on craigslist. Took it for a test drive one morning before work. Fast car. 351 Cleveland. I had planned on meeting the guy again after work. For some strange reason thats still to this day beyond me, I stopped in Hillsboro MotoSports on the way home from work. I had 6 Grand on me. There was a left over '05 sitting by the front door. It was on sale for $4999. It was $5499 OTD. I didnt even look at anything else. I knew nothing about quads accept I thought it really looked coool and I had the money in my pocket to buy it. I was sitting on it when the salesman walked up and asked... "Can I help you?" Without hestitation I pulled 60 Ben Franklins outta my front pocket and said "I want this Quad. Load it up in my truck." It was just about dark by the time I drove away from the shop. BTW, I didnt bother to ask my ol lady if I could buy it. LOL. Anyway, I took it by the house and showed her. She was kinda stunned but not mad. We drove over to a friend of mines house and unloaded it. I took it to the field across the street from his house. HOLY CHIT!!!!! I was surprised by the power. I had it for about 2 weeks and took it to Sand Lake. I was there a few hours and rolled it on a banked turn at the top of the bowl right before you get to the one-ways. When it rolled, I flew off and landed on my belly. The quad came bouncing and landed on my back. For a month I couldnt even walk. I was scared of it. I considered trading it for a 250EX. Went back to the shop. The salesman said..."Dude!!! You dont want a 250EX!!! Trust me. Just get used to it" I still wasnt convinced. I put it on craigslist for $4000. Calls were coming in. I had a guy that wanted to come look at it that evening. I decided to take it for one last ride at Browns Camp before I sold it. I was still afraid of it. After about 5 minutes I started feeling comfortable on it again. I decided right then, I loved my Honda 450 and would learn how to ride it instead of selling it. That was late Nov of '06. Work was slow for a Painter in Oregon. My new job everyday? Going to Browns Camp and ridding my Quad. I bought my Girl Friend an '02 Blaster. I rode my 450 for 4-6 hours almost every single day for 3 months. And yes, I know my way around Browns Camp pretty well. LOL. In March I bought her an '06 TRX250EX (Thank God I didnt trade my 450 for one of those) LOL Since then, I have become totally addicted to quads. I love them. Couldnt imagine not owning at least one quad. Luckily I have two. My "07 was $6500 OTD in July of '07. Bought it for my Girlfriend. Traded in her 250 EX. A month later we broke up. So, I wound up with two Honda 450's.
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By jmeier1981
Ok so I bought the 05 brute force and after putting about 60miles on it I have some concerns.
The engine seems to run REALLY HOT, like almost burnning my legs through my jeans hot but no warning light comes on and it doesnt seem to "act" hot is this normal, does it have any saftey feature to prevent over heating or heat damage?
It also seems to have a slight miss, or hesitation? When you slightly crack the throttle open and hold it at a steady RPM to give it a slightly higher idle it will run smooth for a couple seconds then miss and sometimes backfires. It also seems to sometimes have a hesitation if you jump on the throttle, what could cause this?
Also a couple times when shifting from reverse to high it sounded like it got hung up in between and there was a slight squeal as if maybe the belt was slipping and there was also a slight burning plastic of rubber smell. The belt IS new and it doesnt feel as if it is slipping when accelerating and the belt light hasnt come on.
Anyone have any suggestions?
It does seem to run really well and HARD accept for the slight hesitation or cough and the occasional backfire, I ran it up to 69MPH with both me and a buddy of mine on it, combined weight of almost 500lbs
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By picriver
new ignition switch
four wires - green, red black, black with white line
atv four wires - pink, pink with white line, black, red
which is attached to which, please and thank you?
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By Hagbard
Have a long story that I'll attempt to make brief. I picked up what was advertised as a 1987 LT230E with no cam or valve cover, harness dangling, no plastics, and all kinds of slop in every bushing and bearing, but hey, it was free and I love a challenge. Local guy had a couple 87 230E motors he was selling on craigslist, picked up one of those and a pisspounded DG RCM and header for $100. Went through the harness to start sorting things out and noticed a few key differences, like the stator connectors didn't mate up, one round and one square. Rubbed some of the grime off and found a VIN, Lo and behold - I have a 1990 LT160E, not a 1987 230E... By the grace of who knows what, the 230 just so happened to mount up directly to the 160 frame with no mods. Wasn't until I had broken the seal on starting to chase down the harness leads that I found out.
As it stood, advertised as a 1987 230E
After a bit of elbow grease and some eBay raiding.
Made a new seat cover and found a set of plastics, New carrier bearings, and brakes all around.
Pulled the steering and front suspension all apart and gave it some love with new bushings and tie rods
Ordered a small fortune in NOS and China parts from eBay and RockyMountain and after a couple weeks of wrenching and soldering I have a nearly complete wheeler, in pretty decent shape. Cleaned up a Mikuni carb I had laying around and mounted it up with a cone filter and a Lowe's Racing™ intake boot, and fed it some gas, primed the carb and tugged on the started rope a few times, and sure enough it belkched out some soot and fired up, ran for a couple seconds and died. No sputter, just shut off. Checked for fuel startvation, vacuum in the tank, no problems there, plenty of gas in the carb. Suspected clogged air jets, so I pulled it out of the boot and gave it a shot of ether, and it did the same thing, fired up, ran strong for 2-3 seconds and shut off. Then suspected I f*%#ed up the wiring harness somewhere, and re-traced all the leads with my newly colored wiring diagram, thanks to my kiddo's Crayola marker collection, and everything looked good. Started to suspect the CDI, solenoid, or coil might be faulty and was flipping thru the manual when a buddy stopped by with a pair of boat seats for me to reupholster for him.
He's a little bit of a savant with engines and electronics, and he got curious when I told him my predicament. Three minutes later he said "Hand me a pair of needlenose?" which he used to short the neutral switch to ground, and had me give it another tug. Fired up and ran great, no shutting off, so we deduced that the neutral switch must be at fault and after he left, I pulled it off to troubleshoot, and decided to flick the shifter a couple times with it off to see the little nubbin go around in a cricle. It didn't. I should mention at this point that I had previously changed the oil and while doing so, I took the opportunity to adjust the clutch without consulting the manual because I'm the dumbest guy I know. I did it according to the procedure I had learned for the LT185 I have, and figured the adjuster itself looked the same, they must be the same thing. I loosened the 10mm lock nut, and started turning the adjsuter screw clockwise waiting to encounter resistance, and then back it off 1/8 turn. I was really surprised when it kept turning and turning, but figured it must have been WAY out of adjustment, and went on with business. Figured I might need clutch plates at some point.
Encountered this problem, and actually read the manual and the procedure is entirely different, and I realized that I had basically "adjusted" it into oblivion. I have since drained the oil and tried to re-adjust it twice, with no luck. Anyone have any idea what I can or should do to correct the issue, or am I missing something else entirely here? (chain is off and sprocket nut is loose, if that makes any difference.) Any insight or advice would be appreciated, thanks.
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