Gwbarm

WOW! You are efficient, no i havent done any of that, if they say they fit i order them if they dont i take them back. I do agree you can get good bearings a lot cheaper than OEM, good call.

I did finally get the video to load, its like you let go of the throttle slightly every second, while at full throttle, i didnt hear a backfire. Do you recall whaat size main jet it had in it, but it could be not getting enough fuel to the carb fast enough as Mech suggested.

Great video! Thanks for sharing. Those guys are like a 2 man wrecking crew, they definately knew what they were doing, did a great job, never seen anyone use a claw hammer to install bearings, but whatever works. Good size job but it will be right when you finish. and it definately needs it.

Will it stop cutting out if you let off the throttle a little, or continue.

I couldnt get the videos tpo load but no it should not be cutting out

True, it shouldnt be cutting in and out.

I agree Brakes and bearings would be good. Usually the brakes are packed so tight with dried mud and stuff they will hardly move, yours is moving good. It was hard to tell exactly where the play was coming from on the video it actually appeared that the whole axle was shaking, so is your play from left to right or up and down.

That doesnt sound bad at all, there could still be a carb issue, but we know that this isnt the carb that was factory installed on the Quad. The top speed of that bike fresh off the showroom floor was 45 MPH. With age and wear and other issues(carb) it sounds just about right. Plus is the speedometer still dead accurate.

I meant part # 7 in the diagram, but you have it with the new filter from amazon, great i didnt know they came with that part, no i didnt mean you should buy that part thats why isaid you could adapt it but dont have to with that filter, nice kit, i must have missed that when i was adapting one to my Big Bear, but it mounts differently from mine, good find! The shocks you found look nice i would measure the ones on there now to see if they are close to the same, may work they are adjustable to some degree.

The air Box has its own little seal that fits in the grove for a watertight seal. I also noticed you didnt get the filter adapter left top, no biggy a lot of the newer filters are self supporting now so you can figure out how to adapt it, it is still available from yamaha 75.00 the seal is also still available. Clamp is also still available. Lucas makes good products, good choice. Not really sure about the rubber part i could not find it on the air box diagram bit it appears to be a smaller hose adapter or clamp. I havent bought any shocks lately, but they are expensive, many aftermarket ones on Amazon, you can just measure yours or find ones that fit a 90 model. You are moving right along! Great work! This diagram is from a 92 model like the one you purchased you can look it up on any OEM parts dealer Like Motosports, Rocky Mountain, or Parzilla

Thanks you!

The problem with this one is i cannt just go out and tinker and come back in and figure it out, its a few hrs away, but iv been seeing my brother spend a lot of money to get it repaired and the repair will last about a year with very little use, its mainly used as a utility vehicle pulling stuff around the property, no mudding or high speed riding., So i decided i better get involved to try and figure out whats going on. Im trying to gather up all my parts before i go. I found a used honda starter on Ebay, very reasonable, with the correct part # for an 86. I dont generally buy used starters, but new OEM is unobtainable. If need be i will rebuild it if possible. I found the honda gear like the one that was chewed up, although Calric makes the gear and starter to fit, might should have gone that route but will see how it goes. Im also going to do the kickstarter while im there, i have been thinking about it a little. The kick starter just kicks down easily and doesnt turn the engine, no noises or grinding or anything, and springs back up good. So i was thinking maybe the one way bearing has quit working, any thoughts on that.

Its always possible it could be a replacement engine, i never thought in that direction, only because it was only a year old when my father bought it, but it was used hard, infact the kickstarter has never worked and he never got that fixed, im going to be fixing that also. Clarification on the bypass gear, you think having more teeth on the gear would be a plus.

I also checked the crankcase cover also different part numbers from 86 to 87.

I did check and the starters from 86 and 87 do have different part numbers.

Good point! I havent checked that but i will.

I agree from the looks of the broken gear teeth, it looks like it needs the longer pinion starter, but all the information i have found says the 86 uses the short pinion starter and the longer one started with 87.

I just found it out when i was trying to purchase a starter the 85-86 had a shorter shaft and shared many parts with the 3 wheeler Big Red 250, what i ddont know is if all the 86s were like that or if they changed somewhere in the middle of the model year. I also found out that the aftermarket gear has 46 teeth and the honda one has 43 teeth. The honda one is still available so im going to go with that one and try to find a used denso starter and get back to all honda parts and see if that fixes the problem.

I had the same problem with mine and ended up replacing the keyswitch, and both relays before icould get it to power up. They are the 2 black boxes next to the battery tray.

Thanks! I will check that, and there are 2 different starters, if the wrong one was put in the gears may not mesh right, the one for 85 and 86 had a shorter shaft than the 87, i didnt get it completely out to check, i got it loose only to find i can only get it all the way out by taking everything above it out and ran out of time.

Im sure you are right Mech, most of the manuals i read are from the 60s and 70s, i should not have made that comment, because i really havent looked at any modern manuals, i think the last one i used for any length of time was for the Yamaha and it was 25 years old. My problem with it was it took me forever to find what i was looking for, i could just do it quicker than it would take me to find the section in the manual, i dont look at them everyday so im sure its from inexpierience.

I knew that when i sent it, i was really sending it for reference, according to motosport thats the carb that came on it from the factory. Glad you got it running better, keep up the good work and you will be riding soon.

I finally got around to working on the TRX, this has been an ongoing problem with this machine. This is a machine that we keep on my Fathers property, i dont see it that often, my brother haad it professionally repaired last year and year before same problem, the new starter gears and bypass gears last about a year and the machine is not used that often, he said he was done with it , so i thought i should go take a look. Sure enough the gears were all malled again. IMG_4910.mov There is some slack in there but most is taken up by the gear cover,if anyone with history with these machines has had the same problem, let me know your findings. Where i am now im looking for finding replacement honda gears on Ebay and try those. I suspect the original was replaced with aftermarket gears years ago and they just worse quality as the years go by.

I did used to have to do that fairly regular on the 60s bikes with the 1 down and 3 up trans, neutral is in between 1st and 2nd, but with ATVs all the way down is neutral and it does go into neutral because i can roll it but the light doesnt come on, so im thinking it may not be completely in neutral, so im going to try to blip it and see what happens.

Yamaha starter cutout relay would cause what you are describing. If it wont start when you pull the front brake lever.