Hi guys. I bought a 1987 TRX350D Foreman that I have been trying to fix. It has a couple of issues I need advice on.

First problem:

When I got the 4 wheeler the coil was removed and the plug boot was missing, so I hooked up the coil and connected the plug wire directly to the spark plug and got good reliable spark and was able to get it running by spraying lubricant into the carb. The fuel cut relay was missing so it wasn't getting fuel, so I wired the fuel pump to the battery and was able to ride the 4 wheeler up and down the street about 10 times before the carb finally overflowed.

I ordered a brand new fuel cut relay and installed it along with a new NGK spark plug boot and NGK recommended spark plug: DR8ES-L
It would not start after this. I cleaned the carb very well, and it's getting fuel, but the spark seems to be intermittent now. Since I had it running for 20 minutes or so I believe the CDI and regulator/rectifier are both OK. Are there some grounds somewhere that I can clean?
And what about the trigger coil, and stator, how do I test those?
Someone said something about two types, one AC one DC. I'm confused.
Oh. I also installed fresh fuses in the fuse block.

Can someone please help diagnose the problem?
I've spent many hours trying to get the ATV running so I can use it for hunting.
Did some other maintenance to it:
Changed the oil and put in 20w50 along with a fresh oil filter.
The engine took 2.5 quarts of oil, is this the correct amount?
Also installed a new fuel filter, and have a new UNI air filter but have not installed it yet.



Second problem:

I cannot get the brakes to bleed. I flushed the lines with DOT4 fluid and it comes out clean at both sides. Used more than one bottle of fluid and could not get it to bleed, the lever has to be pumped up and it loses pressure after a few seconds. I tried loosening all banjo bolts including the one where the brake lines meet. Is there a certain sequence I should try?

How do I know if I need to rebuild the master cylinder or if a wheel cylinder is bad?
I don't know how to test either part.

Thanks! [img]i/expressions/beer.gif[/img][img]i/expressions/beer.gif[/img]


PS. I took a picture of a nice TRX350D Foreman from ebay to make my avatar icon. haha [img]i/expressions/face-icon-small-smile.gif[/img]

 

I'm not that familiar with that particular machine, so as far as the igntion goes all I could say is make sure every connection is bright and clean, and there is a good ground. Looking at the spark isn't always a reliable way to tell if you are getting good ignition.

On the brake issue, I'd highly recommend getting a Mity-Vac little hand vacuum pump. It comes with a bunch of fittings and a little catch jar, and the nicer one comes with a gauge. It really works well for bleeding brakes, and makes the job much easier, especially when starting from a dry system.

If you vacuum bleed, you may need to put plumber's tape along the treads of the bleeder valve (and don't get any on the part of the bleeder that seats to seal). That way it will draw fluid through the brake system, and not air around the bleeder valve's threads.

Usually wheel cylinders leak when they go bad. Master cylinders also often leak when they fail, or sometimes the piston won't return fully and it won't open the port to let fluid in to the cylinder from the reservoir.

Good luck, and welcome to the forums.

 

Thanks Jeff. I'll head out and buy one of these vacuum bleeders today:
http://www.harborfreight.com/c....taf?Itemnumber=92474

Will let you know if it works.

My main concern is getting it running. Can anyone help?
I dont know where all the grounds are without taking all the plastic completely off and tracing the wire harness.

 

GOT NO SPARK, sometimes it does, sometimes it doesnt. It was running for 20 minutes, what is wrong?

Got the brake bleeder but it is dark out so I cant do it until tomorrow.

 

still no spark [img]i/expressions/face-icon-small-frown.gif[/img]

 

I was hoping someone who has messed with the ignition system on one of those would have replied...

I assume there's a ground wire on the ignition coil, or it may ground via the mounting bolt? You might also be able to take an ohm meter reading across the coil. I'd expect a few ohms, and if it is totally open that would be a good indication the coil is the cause.

The manual for my 500 describes using a peak voltage tester to determine if the pulse generator is working.

 

Was able to test the coil and make sure everything was properly grounded.
It has zero spark now. I cant test the pickup coil without tearing it apart.
I'm guessing the cdi is bad. Doubt anyone has a spare.

 

NEED CDI..... anyone? [img]i/expressions/face-icon-small-sad.gif[/img]

 

Still experiencing a no-spark to intermittent spark problem.
Charging system measures 330ohms, out of a range of 300-360
New plug cap, new plug, clean body ground. (one under the seat)
Rectifier/regulator properly grounded. All fuses good.

 

Ordered a new CDI....
1987 TRX350D CDI part # 30410-HA7-751

Cost is going to be between $105-$110 bucks shipped.
I will let you know if this fixes it.