2005- 2011 Honda Foreman 500 engine removal

[@allenpashley1079]

That was a FANTASTIC video!!! You didn’t introduce us to your pet cat or anything. There was no nonsense or fed air. It was quick and efficient. Among the best videos I have seen. Thank you so much!!!

[@FourwheelerDoctor]

Thanks and thanks for watching.

[@rodwade2480]

I am going to do a rebuild on my honda 500. Your videos are awesome and very helpful. I have watched most of them several times and look forward to your new ones. I wouldn't do the rebuild if it wasn't for your videos. Thanks man!!!

[@maxedge1449]

Thanks man very informative everything I needed to know in one shot I'm swapping my engine into another frame because my frame rusted out by the lower control arms

[@zachwood3670]

Thanks man I broke the shift fork on my 07 foreman and this helped a lot

[@yourblueeyes1]

Great video of the engine removal! Thank you

[@yeahright302]

good job,doing one of those myself,damn hondamatic went out on my 01 500 rubicon.

[@FourwheelerDoctor]

Did you find a replacement Hondamatic?

[@jamesnorthcutt6895]

Do you have a video on replacing a clutch on a 04 foreman Rubicon 500? I've replaced a few clutches on foreman 400s and 450s but never a 500 just didn't know how complicated it was to get to the clutch on the 500s?

[@FourwheelerDoctor]

No I don't. There aren't many of those old body style Rubicons still around here so I rarely get one in the shop. The closest thing I have is a rancher 400at build which I think I have a video for. It has a similar clutch set up. I will send you a link.

[@FourwheelerDoctor]

I'm sorry but I can't seem to find the video. It must have been a long time ago right before I started videoing my rebuilds

[@jamesnorthcutt6895]

@@FourwheelerDoctor ok no big deal I think I can do it just didn't know how everything was inside there. Thanks

[@maximusfuscus]

Great! Do you have a video for replacing the first gear in a 2005 Foreman 500, manual? The rest of the gears work fine. Any advice would be much appreciated! Subscribed, shared.

[@FourwheelerDoctor]

This engine has a broken tooth on first gear and I replaced it in this video. kzbin.info/www/bejne/p6S9aqasbM9nZs0 Also check out my disassembly video for this same bike to show how to tear it down. The way I understand it this is a common problem with these model foreman. This bike is an es model but the engine internals are the same as yours.

[@maximusfuscus]

@@FourwheelerDoctor - Thank you sir!

[@johnkyle9253]

Great video. Just need some advice. I have an 09 500 Foreman that ran hot and I guess the clutch seized up. The centrifugal clutch works fine, but it jumps pretty good as you’re shifting gears. Any suggestions would be a great help. Thanks

[@FourwheelerDoctor]

It is probably your change clutches that have gotten hot and seized up. Pull the change clutch off and check the friction disks and clutch plates.

[@johnkyle9253]

@@FourwheelerDoctor Yep. Will pull the engine and check it out. Thx

[@FourwheelerDoctor]

@@johnkyle9253 you can get to it without pulling the engine.

[@johnkyle9253]

@@FourwheelerDoctor Change clutch?? Is there a video for that or diagram for the location of the change clutch? Haven’t worked on a lot of these.

[@FourwheelerDoctor]

@@johnkyle9253 check out my engine disassembly video. The clutches are behind the front cover. I very seldom replace the change clutches so I don't have a video just specifically for them

[@kyrahart6109]

Have a 2008 Honda foreman 500. Would a foreman 400 fit? Engine mounts look very similar and everything looks the same, electrical coming out of engine.only need rear wheel drive

[@FourwheelerDoctor]

I can't say I have ever made that swap before but I can't think of anything that would be different except possibly the engine mounts and you would need to swap out the carb on to the 400 or at least change the jets. If you do it please let me know if it works. Because if it does theoretically you could swap from a 400 to a 500 which would be a nice upgrade.

[@kyrahart6109]

Yes I will be looking into it today. I have the engines side by side and they're are very close. The only real difference I see is that the front driveshaft splines coming out of engine are shorter on 400

[@kyrahart6109]

Update: the 400 motor mounts are very close but slightly different. I got the 400 motor bolted in the by 500 frame by cutting off the engine mounts on the right side and top. Used the existing left lower mount. And rewelded them in place. Everything from the 500 I used; stator, pulsar coil, pull start, carb, and left the full harness. Rear axle slides right in. My problem now is there is no spark. The circle white plug is the same on both engines but the 500 has a 7 pin connector shown at 9:40 and the 400 does not have that plug . My neutral light is also not lit on the indicator. Turns over but no spark

[@kyrahart6109]

On the 400 frame the lower engine mounts are straight up and on the 500 the right side engine mount is leaning out to the right 1/2". So I cut the mount and put it straight up like the 400 and the Axle is still straight.

[@FourwheelerDoctor]

@@kyrahart6109 I checked the schematic and the 7 pin connector is for the gear position switch. Is the 400 engine a foot shift? It is probably just a matter of connecting two wires for the reverse and neutral to make the lights on the dash come one. I have schematics for both bikes. I'm not 100% sure but there is a good chance that it's not firing because it doesn't think it's in neutral.

[@boneheadd911]

THANKS

[@colonialroofingofnorthcaro441]

I've got the weirdest thing, 2005 500 foreman, crank with one turn of the engine, put a new piston and cylinder and rings on , put everything back together and know it want run, it will start and idle for few mins, but as soon as I try to give it gas it just cuts off with a little puff of exhaust out the carb, but not everytime, so weird to run so good, change nothing but a top end other then valves, which didn't do anything with them other then some cleaning carbon off, put it back on, timed it up and gaps the valves, and it want run, just don't get it as good as it ran before, if you have any ideas I'd get appreciate it, somebody said could be electrical, but can't find anything, plus why would it be electrical when I didn't touch any electrical, just new bucket and piston, thanks

[@FourwheelerDoctor]

Have you rechecked the valves since you have had it running

[@timothygores7770]

So I bought a 2003 Honda foreman rubicon 500 and when I put it in drive or reverse it also makes a grid noise so I was wondering if looking that the transmission would be better or looking at the differential first

[@timothygores7770]

And I can start it up and have it warm up amd then I can drive it with little grid but stills grids

[@FourwheelerDoctor]

If it's a Rubicon I would bet it was the Hondamatic unit in the transmission just because these give a lot of problems. It is hard to say without hearing it but hopefully you lucked up and it's just something in the diff because transmission problems can get expensive.

[@Localoutsider999]

Please tell me if you can put a 500 engine on a 420 body I got perfect honda 420 and good Honda 500 engine need to know asap @four wheeler doctor

[@jasonlewallen7146]

Absolutely 👍🏼

[@arkansasgamer895]

I know this comment is way late and you probably won’t reply but I have a 2005 Foreman 500 2wd. Has a crank no spark issue. I was told it’s probably the Stator on the back of the motor. I was told to either remove the motor or the rear A arm assembly. I just watched this video and I definitely DON’T want to pull the engine. Thoughts?

[@FourwheelerDoctor]

In my 16 years of working on these, I have never replaced a stator for a no spark condition. It is normally either the CDI, coil, rectifier, kill switch, ignition switch or the spark plug. I'm not saying it may not be the pick up on the rear of the engine but in my past experience its hasn't been common.

[@arkansasgamer895]

@@FourwheelerDoctor Thank You for the reply. I know my Ignition Switch needs replaced as I have to jiggle the key to get the Neutral light to stay on. I will also start with a new plug. From there I will try coil. I’m really hoping it’s not the Computer. I will keep you posted. Thx again!!

[@arkansasgamer895]

@@FourwheelerDoctor Haven’t had much time to mess with it but here is my diagnosis. In-line tester shows no spark out of the plug or the coil. All fuses are good. Battery is new/charged. The power wire that goes to the coil doesn’t light up with key on or turning over. Dealership said it’s most likely the computer in front of the handle bars or it’s the stator on back of the engine. I don’t know how to use a volt meter properly to check. Not sure where to go from there.

[@heat19721]

I have 2011 Honda foreman 500 manual shift, and it started making a noise and stopped pulling, where do I need to start on finding out what is wrong, it is at 9,000 miles on the engine?

[@FourwheelerDoctor]

Is the output shaft coming out of the engine spinning when in gear. Does 4x4 not work either? Is the neutral light showing on the dash?

[@heat19721]

@@FourwheelerDoctor yes the 4x4 front works, that's how I got it home, but I took the rear end out yesterday and I could spin the driveshaft freely and the axle wont turn so I pulled the axle and housing plate and it appears that the axle and the inner housing big gear is worn down on the spline, Do u know the parts I need to get to fix it?

[@FourwheelerDoctor]

@@heat19721 usually I would replace the ring gear and the axle shaft in that case. Normally that comes from the left seal out by the left rear wheel going bad and letting mud in the tube. So it probably needs to be replaced and the bearing out there too. The Axel and ring gear from Honda or about $150 a piece. You might can find aftermarket parts on eBay much cheaper if you want go that route. The part number for the ring gear is 41431-HP0-A00 the part number for the axle shaft is 42311-HN2-020. Also have a video rebuilding one of these. So check that out too

[@heat19721]

@@FourwheelerDoctor hey brother, thanks for all the info and I was wondering how do you change the big gear, does it have to be pressed on n off or can you do it with like a big socket etc?

[@FourwheelerDoctor]

@@heat19721 if it's the ring gear you are talking about, you can knock it out with a big socket stuck in where the axle would go.

[@bummysop]

About how much it cost to replace a crack shaft on a 08 foreman 500 ? thanks.

[@FourwheelerDoctor]

The crankshaft for these are around $500. By the time you put rings in it or bore it, replace cam chain, oil pump, and gaskets you might have close to $900 in a full rebuild for just parts.

[@bummysop]

@@FourwheelerDoctor thank you for taking the time to reply,,you have great informative videos,keep up the good work 👍.

[@FourwheelerDoctor]

@@bummysop thanks man. Thanks for watching

[@henrypenner9370]

Appreciate man 👍

[@big_watson2015]

Sounds fine to me

[@jacksonstephens9772]

These bikes give me migraines and nightmare

[@cryptoking7875]

Wanna come do mine? 😂