how to adjust the float on a trx 300

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Adjusting the Pekar K68 for Dnepr or Ural

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Filed Under (Tips and Review) by admin on 11-11-2010

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1. Make sure the ignition timing is correct 2. Adjust the valves as necessary to ensure proper operation 3. Run the engine to warm it up a bit 4. Adjust the float setting. To do this, remove the carburetors (leave the throttle cables attached), remove the bowl and turn the carburetor upside down (fuel will spill). The float should look like this: Adjust as necessary by bending the float support (#37 in Figure 1). Reinstall Installation and idle adjustment 1. First you must adjust the idle. It is acceptable per the manual to adjust the idle by using the idle adjust screws (11). This usually involves screwing them then backing out 1 to 1.5 turns. Or you can adjust looking at the sliders 2. If installing the carburetors: a. Remove the cover (2) b. Reomve the slider (3) c. Place the throttle cable through the guide (18) with the spring (4) on the cable. d. Route the cable through the slide catch (6) e. Insert the slide assembly into the chamber and make sure it easily slides up and down. Direct the needle (8) into the opening of the diffuser (angled side visible). f. Screw assembly together and verify via throttle movement that slide moves freely. Attach fuel delivery lines to (12). 3. Using the idle set screw (11) raise the slider so the lower edge is 1-2 mm. 4. Assemble to engine using the proper gaskets (paper – felt – paper). 5. Using the locknut (26) adjust the free play of the throttle cable (2-3 mm) 6. Adjust the idle mixture screw – turn in completely then out 1 to 1.5 turns. * Starting using the K68′s (cold weather) 1. Verify fuel flow. Apply choke (pull 52 in Fig1). 2. Using the ticklers (13) allow fuel to enter the bowl until fuel drains from (14) 3. With the ignition off, kick 1 or 2 times 4. Turn ignition on, and as soon as engine is warmed up (maybe sooner) push choke mechanisms to open choke Idle Adjustment (engine running and warm) 1. Remove one of the spark plug caps, and with the cap shorted, adjust (11) to decrease RPM’s to a point of being minimally steady. 2. Adjust the mixture (15) out until RPM’s decrease. Turn in until RPM’s increase slightly. Then turn in screws ¼ to 1/3 revoultion. 3. Do the same for the second carburetor with the first spark plug cap shorted. 4. With both cylinders, adjust each idle (11) on each carburetor the same amount each until it’s at a steady, minimal RPM. Use small changes. (at this point you can use your airflow tool to check). 5. Sharply increase, then decrease throttle. Then engine must return to low RPMs smoothly. If the engine goes below limits, readjust (11) from step 4. Synchronization of the K68 Note: Rather than using the opposite cylinder shorted to test the pull of the live cylinder carburetor, you can use something like a Twinmax connected to the test ports (27 Fig 1). Or, if you have a model without these ports, use a Synchrometer (Appendix 2) held against the face of the carburetor. These tools merely show airflow passing through each carburetor (which is dependent on the position and wear on the slide). If using these tools, it’s not necessary to do the following steps. You wil want to use a throttle guide (Appendix 1), to show airflow at various throttle settings. Using the flow meter of your choice make sure each carburetor is the same at the various throttle settings. 1. Place the motorcycle on the center stand ensuring the rear wheel is suspended 2. Make sure you have large area to work with (safety issues here) 3. Shift into the highest gear with the engine running 4. Short one spark plug cap to the cylinder (using a nail or something in the fins) 5. Increase the speed to 40-50 km/hr 6. Fix the throttle using the throttle (maybe using a throttle stop screw under the throttle housing). 7. Reconnect other cylinder and using the opposite carburetor determine the speed which should be the same as the first. 8. Adjust the position of this slide to achieve the referenced speed using the locknut at the top of the carburetor.

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Triumph Bonneville Tuning Manual

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Filed Under (Triumph) by admin on 20-11-2010

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1. The Float The float bowl acts as a fuel reservoir to meet engine demand. The float is hinged on a pin in the float boss. It rises and falls with the fuel level in the float bowl. The small metal tang integrated in the plastic float supports the float valve, also known as the float needle. As the fuel in the float bowl rises, the float valve is pushed into the valve seat, until it’s high enough to shut off the fuel flow to the bowl. As fuel is used the level in the bowl drops lowering the float which pulls the float valve from its seat, and fills again. Adjusting the height of the float has a big effect on the mixture as a low or high float level makes it harder or easier for the vacuum to suck fuel into the venturi. Differing float levels cause an imbalance which may be perceived as vibration. 2. The Choke This system is referred to as the choke. But that’s a misnomer. When you pull the choke knob, what you’re doing is retracting a plunger that opens a tube connected to the starter jet, allowing additional fuel to enter the venturi just below the vacuum hose nipple. It supplements the pilot system at start up. 3. The Pilot System The primary purpose of the pilot system is to supply the mixture at idle. It continues to supply fuel throughout the entire throttle range, but after about 1/8 throttle is reached the main system starts to put out more of the total mixture, up to full throttle. By adjusting the idle with the big screw on the left side of the carburettors the position of the butterfly is altered, so exposing one or more of the four small holes that are drilled into the venturi, (leading to the pilot jet) just under the butterfly valve, letting more or less air pass the butterfly. Adjusting the pilot screw that’s under the carburettor varies the amount of air premixing with the fuel before it enters the venturi. 4. The Main System Open the throttle and the cable that’s connected to the butterfly valve turns it from vertical to horizontal, so letting more air through the venturi. This increases the vacuum effect that is transferred up through the vacuum drilling in the slide to the diaphragm valve that leads to the diaphragm chamber. The top chamber is separated from the bottom by a rubber diaphragm. The bottom chamber is open to atmospheric pressure from the airbox. When the vacuum in the top chamber rises enough, the constant ambient pressure of the lower chamber helps the diaphragm valve overcome the downward force of the diaphragm spring, so it rises from the ven- turi. As the diaphragm is raised the needle is pulled out of the needle jet, exposing a thinner portion of the needle taper which allows more fuel to rise into the venturi to meet the increased engine demand. The key parts of the main system are shown in the photo below

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KYMCO MAXXER 300/ 250 MONGOOSE 300/ 250 SERVICE MANUAL

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Filed Under (Kymco) by admin on 26-10-2010

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apply or add designated greases and lubricants to the specified lubrication points. ÑAfter reassembly, check all parts for proper tightening and operation. ÑWhen two persons work together, pay attention to the mutual working safety. ÑDisconnect the battery negative (-) terminal before operation. ÑWhen using a spanner or other tools, make sure not to damage the motorcycle surface. ÑAfter operation, check all connecting points, fasteners, and lines for proper connection and installation. ÑWhen connecting the battery, the positive (+) terminal must be connected first. ÑAfter connection, apply grease to the battery terminals. ÑTerminal caps shall be installed securely. 1 . GENERAL INFORMATION 1-6 ATV 300/250 ÑIf the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. ÑAfter operation, terminal caps shall be installed securely. ÑWhen taking out the connector, the lock on the connector shall be released before operation. ÑHold the connector body when connecting or disconnecting it. ÑDo not pull the connector wire. ÑCheck if any connector terminal is bending, protruding or loose. Confirm Capacity 1 . GENERAL INFORMATION 1-7 ATV 300/250 ÑThe connector shall be inserted completely. ÑIf the double connector has a lock, lock it at the correct position. ÑCheck if there is any loose wire

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KAWASAKI TERYX EFI Installation Instructions.

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Filed Under (Kawasaki) by admin on 08-02-2011

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Basic Tuning Adjustments 1. The following instructions are for basic fuel tuning. Modes 1,2, & 3 are allowing adjustments to increase and decrease the amount of fuel the engine needs. Modes 4 & 5 are for advanced tuning only. DO NOT change modes 4 & 5 when doing basic tuning! 2. To help understand how these modes work, you can think of them as if you were working with a carburetor. 3. Remember each time you push the MODE button you will be advancing to the next mode. Push the MODE button once and you are now in mode 1, push the MODE button again and you are now in mode 2 and so on. You only need to be concerned with modes 1, 2 & 3 for basic tuning. Modes 4 & 5 are for advanced tuning ONLY. 4. If you need to go back to the settings that were pre programmed when you purchased the controller, just look at the picture in each mode, the colored square represents where the settings were when you purchased the controller. 5. Looking at the controller you will see eight lights with numbers under them, this is what you need to look at when changing settings. The #1 light on the controller represents the leanest setting. TRINITY RACING DOES NOT TAKE REPONSIBLITY FOR DAMAGES THAT MAY OCCUR DURING OPERATION OF YOUR VEHICLE UNDER IMPROPER JET SETTINGS. IT IS THE FINAL RESPONSIBLITY OF THE OWNER/RIDER TO ADJUST JETTING TO SPECIFIC RIDING CONDITIONS AND ELEVATION BEFORE RIDING. WARNING! 1.877.FAS TOYS 2.Remove both seats 6. Re-install engine cover and seats. 6. Mode 1 green light represents idle & cruise adjustment (i.e. pilot jet). To adjust this setting push the MODE button once and then push the plus or minus buttons to adjust fuel as needed. 7. Mode 2 yellow light represents an additional amount of fuel added during acceleration (i.e. needle position). To adjust this setting, push MODE twice and then push the plus or minus buttons to adjust fuel as needed. 12 34 56 7 8 12 34 56 7 8 8. Mode 3 red light represents more fuel being added during full throttle (i.e. main jet). To adjust this setting push the MODE button three times and then push the plus or minus buttons to adjust fuel as needed. 9. If you are confident about your tuning skills and feel you need to adjust other parameters, see Advanced Tuning. 12 34 56 7 8 Advanced Tuning Adjustments 1. Advance tuning has two modes in which to adjust. They are called mode 4 and mode 5. In basic tuning, you are changing the amount of fuel that the engine receives, but with advance tuning, you will be changing when the fuel will be available. In each mode you can adjust how soon the fuel delivery occurs. 2. Mode 4 yellow light and blue light represent when the fuel delivery is available during partial throttle acceleration. To adjust this setting, push the MODE button four times and then push the plus or minus buttons to adjust fuel as needed. Only the yellow light will be changing.

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HONDA TRX 650 RINCON 4X4, TRX 680 Rincon BLADE HARDWARE MOUNTING REMOVAL AND INSTALLATION MANUALS

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Filed Under (Honda) by admin on 26-12-2011

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Push tube/ Swivel/ Blade Assembly Instructions 1. Install the blade swivel (15) onto the front of the push tube (14) using the 1/2″ shoulder bolt (4), two 1/2″ washers (5), and a 3/8″ Nylock nut (3) from the bolt bag per diagram #1. Make sure the flat washers seat properly on the bottom of the shoulder bolt while tightening the nut. Make sure the blade turns freely. 2. Remove the 2 bottom flanged nuts (I) from the u-bolt (D) and 2 from the 3/8″ bolts (H) on the blade position pin assembly (23). Run the 2 top flanged nuts up the threads of the u-bolt. Place the blade position pin assembly on the push tube as shown in the Diagram, sliding the blade position pin through one of the oval holes on the swivel and through the rear blade position pin support bracket on the push tube. 3. Re-install the u-bolt and 3/8″ bolts and flanged nuts per the Diagram. On the u-bolt, thread the bottom nuts up until they are flush with the bottom of the threads then run the top ones down, making sure the bottom nuts remain flush with the bottom of the u-bolt. Tighten all 4 bottom nuts. 4. Remove the two shoulder bolts (18) from the pivot point brackets on the back of the blade (1). Attach the blade to the swivel by sliding the ears on each side of the swivel into the pivot point brackets on the blade, reinstall the two shoulder bolts and Nylock nut (3) and tighten. 5. Hook the blade springs (6) to the two round holes on either side of the 5 oval holes on the swivel. Hook the eyebolts through the other end of the springs, push the eyebolts through the spring attaching points on the back of the blade and install 3/8″ Nylock nuts (3). Spring tension may be increased by tightening both Nylock nuts on the eyebolts evenly. 6. Install the blade stops (16) with the two 3/8″ x 1″ bolts (17) and 3/8″ nuts (3) per the Diagram. Rotating the stops allows you to change the blade pitch to suit changing conditions or materials

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Kawasaki FI Calibration Tool Instruction Manual

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Filed Under (Kawasaki) by admin on 08-02-2011

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System Function Kawasaki FI Calibration Tool (FI Tool) is developed to modify the mapping of the racing machine to gain operating conditions suitable for the course and the rider’s skill. The following are the available setting functions. Table 1 FI Tool Function Model Name Functions Available Setting Range ’04 ZX-10R ’05 ZX-6RR ’05 ZX-10R ’06 ZX-10R ’07 ZX-6R 1) Adjust the injected fuel rate at acceleration -30 % ~ +30 % 〇 〇 〇 〇 〇 2) Adjust the injected fuel rate of No.1 and No.4 cylinder -30 % ~ +30 % 〇 〇 〇 〇 〇 3) Adjust the injected fuel rate of No.2 and No.3 cylinder -30 % ~ +30 % 〇 〇 〇 〇 〇 4) Adjust the injected fuel rate of primary and secondary injector * -30 % ~ +30 % -10 % ~ +10 % — – — 〇 — – — – — 〇 5) Adjust the ignition timing -15°CA~ +5°CA 〇 〇 〇 〇 〇 6) Adjust the sub-throttle opening angle -50 % ~ +50 % -45 % ~ +45 % 〇 — – 〇 〇 — 〇 — – 〇 7) Adjust the exhaust device opening angle -50 % ~ +50 % 〇 — 〇 〇 — 8) Adjust the all injected fuel rates of all cylinders and operating are a simultaneously -30 % ~ +30 % 〇 〇 〇 〇 〇 9) Adjust the value of engine over revolution limiter 0 ~ +300 rpm -1000 ~ +700rpm -1000 ~+1200rpm — – — 〇 — – — 〇 — – — 〇 〇 — – 10) Set the fuel cut or not at deceleration Use or Not Use 〇 〇 〇 〇 〇 11) Set the sub throttle controlled or not Controlled or Full Open Fixed 〇 — – — – 12) Set the exhaust device controlled or not Controlled or Full Open Fixed 〇 〇 〇 〇 〇 13) Set the Auto Shifter Ignition Cut Length Controlled or not, set Ig. Cut Time by gear range — – 〇 〇 〇 14) Set the Pit Road RPM Limit Controlled or not, set Upper Limit RPM by gear range

Ural carburetors Installation and idle adjustment

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Filed Under (Ural) by admin on 02-11-2010

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1. First you must adjust the idle. It is acceptable per the manual to adjust the idle by using the idle adjust screws (11). This usually involves screwing them then backing out 1 to 1.5 turns. Or you can adjust looking at the sliders 2. If installing the carburetors: a. Remove the cover (2) b. Reomve the slider (3) c. Place the throttle cable through the guide (18) with the spring (4) on the cable. d. Route the cable through the slide catch (6) e. Insert the slide assembly into the chamber and make sure it easily slides up and down. Direct the needle (8) into the opening of the diffuser (angled side visible). f. Screw assembly together and verify via throttle movement that slide moves freely. Attach fuel delivery lines to (12). 3. Using the idle set screw (11) raise the slider so the lower edge is 1-2 mm. 4. Assemble to engine using the proper gaskets (paper – felt – paper). 5. Using the locknut (26) adjust the free play of the throttle cable (2-3 mm) 6. Adjust the idle mixture screw – turn in completely then out 1 to 1.5 turns 1. Remove one of the spark plug caps, and with the cap shorted, adjust (11) to decrease RPM’s to a point of being minimally steady. 2. Adjust the mixture (15) out until RPM’s decrease. Turn in until RPM’s increase slightly. Then turn in screws ¼ to 1/3 revoultion. 3. Do the same for the second carburetor with the first spark plug cap shorted. 4. With both cylinders, adjust each idle (11) on each carburetor the same amount each until it’s at a steady, minimal RPM. Use small changes. (at this point you can use your airflow tool to check). 5. Sharply increase, then decrease throttle. Then engine must return to low RPMs smoothly. If the engine goes below limits, readjust (11) from step 4. Synchronization of the K68 Note: Rather than using the opposite cylinder shorted to test the pull of the live cylinder carburetor, you can use something like a Twinmax connected to the test ports (27 Fig 1). Or, if you have a model without these ports, use a Synchrometer (Appendix 2) held against the face of the carburetor. These tools merely show airflow passing through each carburetor (which is dependent on the position and wear on the slide). If using these tools, it’s not necessary to do the following steps. You wil want to use a throttle guide (Appendix 1), to show airflow at various throttle settings. Using the flow meter of your choice make sure each carburetor is the same at the various throttle settings. 1. Place the motorcycle on the center stand ensuring the rear wheel is suspended 2. Make sure you have large area to work with (safety issues here) 3. Shift into the highest gear with the engine running 4. Short one spark plug cap to the cylinder (using a nail or something in the fins) 5. Increase the speed to 40-50 km/hr 6. Fix the throttle using the throttle (maybe using a throttle stop screw under the throttle housing). 7. Reconnect other cylinder and using the opposite carburetor determine the speed which should be the same as the first. 8. Adjust the position of this slide to achieve the referenced speed using the locknut at the top of the carburetor.

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KTM 250/ 300/ 380 SX,MXC,EXC ENGINE REPAIR MANUAL

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Filed Under (KTM) by admin on 12-11-2010

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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 2-2C main jet jet needle jet needle air control screw idle adjusting screw idle jet throttle valve Idling range A Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2 . Only make adjustments when the engine is hot. To this end, slightly increase the idling speed of the engine by means of the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Create a round and stable engine speed using the air control screw (basic position of the air control screw = open by 1.5 turns). Then adjust to the normal idling speed by means of the idle adjusting screw. Opening up B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised. If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer. Full throttle range D Operation with the throttle fully open (flat out). This range is influenced by the main jet and the jet needle. If the porcelain of the new spark plug is found to have a very bright or white coating or if the engine rings, after a short distance of riding flat out, a larger main jet is required. If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one. mixture too rich: too much fuel in proportion to air mixture too lean: not enough fuel in proportion to air 1 2 OPERATING RANGES OF THE CARBURETOR 2-3C Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20°C (68°F), mainly for off-road use and central European premium-grade fuel (ROZ 95 MOZ). Mixing ratio 2-stroke motor oil : super fuel 1:40 – 1:60. Basic information on a change of the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB:

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Honda TRX 450R BoonDocker Nitrous System Installation Instructions

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Filed Under (Honda) by admin on 12-12-2011

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This nitrous manifold greatly simplifies the way extra fuel is delivered that is needed for nitrous use. The carburetor vents
are connected to this manifold, allowing the carburetor(s) to breathe normally through the airbox when nitrous is not used.
When nitrous is sprayed, the manifold produces a positive pressure that goes to the carburetor float bowl, which “pushes”
more fuel through the main jet of the carburetor(s). This eliminates the need for an extra fuel pump, fuel solenoid, extra
plumbing, and nozzle(s) that are necessary to inject the extra fuel in other systems.This manifold is also designed to vary the float bowl pressure in relation to nitrous pressure, thus keeping the nitrous and fuel delivery in sync. Fluctuations in bottle temperature greatly affect nitrous pressure, which affects nitrous delivery. By automatically adjusting the fuel delivery as nitrous pressure varies, this manifold makes nitrous safe, reliable, and easy to use. The valve shown in picture (A) will require both the 4an x 1/8 npt fitting and the 1/8 npt plug. The valve shown in picture (B) will only need the 4an x 1/8 npt fitting. Use thread sealant on these fittings, be sure not to get any sealant inside the valve. Remove the upper mounting bolts on the front bumper. Install bracket support strap and reinstall the mounting bolts. 2. Install rear strap mounts over frame tubes. 3. Attach saddle bracket to support brackets, front and rear using supplied hardware.

HONDA ATV Carburetor Repair Kits Installation

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Filed Under (Honda) by admin on 21-12-2011

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ATV Carburetor Repair Kits Complete kits to rebuild one OEM carburetor. Each kit contains necessary gaskets/o-rings, needle valve or needle valve set, and jets. Made in Japan. Note: Check all parts before installation. Honda Model Year Order No AT C70 78-85 025-001 AT C90 70-71 025-003 ATC90K1/K2/K3 72-75 025-003 AT C90 76-78 025-003 TRX90 Fourtrax 90 93-98 025-084 ATC110 79-83 025-005 ATC110 84-85 025-061 ATC125M 84-85 025-062 TRX125 Fourtrax 85-86 025-050 TRX125 Fourtrax 87-88 025-063 ATC185 1980 025-009 ATC185S 81-83 025-009 AT C200 81-82 025-008 AT C200 1983 025-009 ATC200E Big Red 82-83 025-064 ATC200ES Big Red 1984 025-064 AT C200M 84-85 025-064 AT C200S 84-86 025-065 AT C200X 83-85 025-012 AT C200X 86-87 025-014 TRX200 Fourtrax 200 90-91 025-066 TRX200D Fourtrax 200 Type II 1991 025-066 TRX200D Fourtrax 200 Type II 92-93 025-067 TRX200D Fourtrax 200 Type II 94-97 025-068 TRX200SX Fourtrax 87-88 025-069 ATC250R 81-82 025-017 ATC250R 83-84 025-018 AT C250R 1985 025-019 ATC250ES Big Red 85-87 025-029 AT C250SX 1985 025-070 TRX250 Fourtrax 250 1985 025-071 TRX250 Fourtrax 250 86-87 025-072 TRX250EX Sportrax 250EX 01-04 025-085 TRX250R Fourtrax 250R 86-87 025-060 TRX250R Fourtrax 250R 1988 025-073 TRX250X 91-92 025-074 TRX300 Fourtrax 300 1988 025-075 TRX300 Fourtrax 300 91-92 025-076 TRX300 Fourtrax 300 93-95 025-078 Honda Model Year Order No TRX300EX Fourtrax 300EX 93-98 025-081 TRX300FW Fourtrax 300 4×4 1988 025-075 TRX300FW Fourtrax 300 4×4 91-92 025-076 TRX300FW Fourtrax 300 4×4 93-95 025-078 AT C350X 1985 025-035 TRX350 Fourtrax 4×4 86-87 025-079 TRX350FE Fourtrax Rancher 4×4 ES 00-03 025-082 TRX350FM Fourtrax Rancher 4×4 00-03 025-082 TRX350TE Fourtrax Rancher ES 00-03 025-082 TRX350TM Fourtrax Rancher 00-03 025-082 TRX350D Fourtrax Foreman 4×4 87-89 025-079 TRX400FW Fourtrax Foreman 95-00 025-080 TRX450ES Fourtrax Foreman ES 98-01 025-083 TRX450FE Fourtrax Foreman ES 02-03 025-083 TRX450FM Fourtrax Foreman S 02-03 025-083 TRX450S Fourtrax Foreman S 98-01 025-083 TRX500FAFourtrax Rubicon 01-04 025-086

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