Frank Angerano

I have had to make a few different types of screwdrivers to get In there while the bike is running.  Each bike is didfent of course.  Even small mirrors to see what I’m doing.   You cannot fully adjust a bike without it running.   I like to hear and feel a change in the engine as you adjust.   And you should clearly see the engine change it’s attitude as you adjust. If not then the air fuel screw needs replacing as it’s worn or damaged.   

Nice looking bike.  Time for some new tires it looks! That Honda bike has always been one of my favorites. All though I love my 4x4’s that bike is my bike of choice for a sport bike. I’ve never heard of the trx 700xx model though. Trx yes but the xx?    I don’t  see it getting to 80 mph but I bet it gets close.  Good luck with it and ride safe.  

Was there another other change in the way the engine ran while making adjustments? The engine should have changed the way it ran worse or rom change ? 

I checked eBay there seems to a few sets of used rims. They range from $85 to $100. 

It’s on the bottom of the carb.  There may be a small metal plug covering up the screw but it’s there someplace.  All carburetors have a mixture screw.   

Also have you checked the manifold that the carburetor mounts to on the engine side for any cracks ?

Ok so let’s go back to the carb. It’s obviously starving for air with the filter box on. Juts because Polaris rebuilt it does not mean they didn’t miss something. Maybe it’s set wrong ?  Any backfires? 

I would try to adjust the air/fuel mixture screw and see what happens.  You should remember where it is before you do anything. Screw it into a snug position but count the rotation of turns to that position and write it down so you know.  This way you can always go back to that setting. Then try setting it at a different point.  For instance if it’s 1-3/4 turns out from snug then go 2-1/2 turns out. Test the bike and keep at it. You will get it.   

It’s just a matter of taking the fuel line that goes to the carb off and putting it in a cup and crank the engine until you see fuel come from the line line in your cup.  Once that’s done you should be good to go.  I like to take the spark plug wire off and tuck it away safe so the bike does not start if you have any fuel left in the carburetor. 

It can also fry the stator coil.   

The only thing that comes to mind is there is possibly a constant pressure that the fuel pump delivers keeping the carburetor properly fueled.   

I would do exactly what you said and start with putting the new pump in and go from there.   See if that corrects the problem.  Is not you will have to go a few steps further and maybe make some adjustments or check the carburetor for an obstruction. 

Keep in mind yiu have to prime that pump before you hook it up to the carburetor.  

Keep us posted.  Good luck.

Nice job! Check eBay you might find a good set of used rims there.  

Was any of this going on before the fuel pump went bad ? 

Also how is the bike running if the fuel pump is bad ? If it’s still running and the pump is not delivering the proper amount of fuel then maybe that’s the cause but I’ve never really seen a partially broken fuel pump.  

There are air intake openings on the air box. Have you checked that they are all clear? 

Also the filter may look clean but may be clogged.   

Tattoo that thing on. No more worries ! 

Start to look at the wire harness for any loose or broken wires.  Kill switch may have an issue.   If not there then the stator coil or secondary coil.   

If you know how to use a tester you can eliminate those parts to avoid buying them. 

Agreed on the jumping a utility quad. Not good, it’s like a ton of bricks coming down.

If you ask any of the members here we would all have different opinions.  Im a fan of Honda’s and will always be.  I’ve worked on everything except the Suzuki’s. Polaris would be my least favorite choice as I’ve seen some repetitive problems.  But they all have little nuances that we’ve heard.   

That’s a great video @davefrombc 👍 good find.  

@JacobSlabach if you ever come across and old bike laying around that’s shot. Pull the motor and split it open.   I did this with my son on a beat up xr80 we found. He split the engine just to see how things work.   I explained as much as I knew and in addition he learned how the clutch worked etc. It was a great learning experience.  

It’s a bi*** but two things have to happen. 

1. You must have the air filter on as if the bike was ready to ride. 

2. You have to make up a small screw driver to get in to the adjustment spot.  I’ve done it  I bought a flex driver which is a small flexibile shaft screwdriver. Or make one up.  

It’s a 500 so right out of the gate you know 1-3/4 will be the minimum. Start there and adjust out.  Keep the idle as lows as possable to keep the bike running. As you adjust the fuel/air mixture screw the bike will rev up as you get better. While this is going on you will have to lower the idle. Keep adjusting until the highest point of reving. That means at some point the engine will not continue to rev higher but start to act up.  Once you hit that point you have passed the sweet spot.  Back it down and make final adjustments.  The highest revs mean the bike is getting the most out of fuel and air. 

Ok Mr Gary we need to figure this out. I know @Ajmboy is a Suzuki guy. Maybe he has some input.  But I would think there has to be a drain plug.  Have you checked the lower sides of the case ? Maybe instead of the bottom ?

The only other thing I can think of is it has to be pumped out.  But I doubt that.  Is there a fill plug for that tranny?

That transmission plug should have a hex head flush type drain plug and it should be on the bottom same side as the fill cap.  Some of the engines on other manufacturers bikes had the gear boxes built right into the engine where the engine oil was also the gear box oil. Both pros and cons . I believe your bike has a separate transmission, locate the fill cap and look under the bike in the same area. 

Is the carb that beat up that it’s byond repair? A valve adjustment would prob help for other reasons but not this problem.   The timing is pretty straight forward as your 300 is. Cam sprocket and T mark on the flywheel.   Double check that the choke is not stuck.   And also check for good spark and a fresh plug. 

Also my 220 ran best on a 1-1/2 turns out on the air fuel mixture screw.  

That is a great question.   It could be that your spark is breaking down at some point and soaking the plug because no or poor spark. Definitely a good possibility.    @06kfx440 👍