shadetree

don't worry about the staked nuts, an air impat gun will zip the nut off, yes, you can re-use the nuts. as for the gear puller ?, it has been used a few times here by a member, myself, i use the correct tool to avoid messing up anything.

ok..yer good on that part.

also, check out the reg/rec, a bad reg/rec will stop it from firing, case in point, watch this video --> No spark problem Fixed!!! 1998 honda foreman 450 better picture - YouTube , he also covers the c.d.i. , but in detail, it was a bad reg/rec.

haha..very true !.

the arm should slide off the shaft, the lower part will not come off unless you have the oil pipe removed. if you are trying to get to the whole shifting parts under the change clutch ?, then yes, you will need to pull the clutches.

if i remeber correctly ?, if the fan control does not work on this model ?, the oil light will not come on shortly, then it won't fire spark plug.

update: placed an order for the clutch parts, decided its best, when tearing it open, may as well just replace the clutches while i've got it apart...whats another 300 or so bucks...right ?..lol.

most of the clutch parts ( arm for sure ) lifts right off the shifting shaft, no need to remove any clutches. but yes...you can remove the clutches without the spec clutch puller tool, BUT !!!, you better have a very good aim/swing in order to hammer the centrifugal clutch off the crank ?!. one good miss, and you will hit the case, and break it !..lol. its best to have the spec tool to pop the clutch off the crank. 27 mm socket to remove the stake nut, comes off easy with an air impact gun.

sec pic might be the fuse holder ?, or starter relay ?. me thinks its the fuse holder.

update: just got off the phone with this owner, he said to order the gear set, along with a spark plug, valve guide seals ( i forgot to order the spark plug and valve guide seals ), soo..the saga continues..lol.

@jeepwm69 , i was wrong, counted wrong gear ?..crap !..and now i've got to tell this guy, see if he wants to upgrade or not ?, got a spare set wanna let go until i get a new gear set ordered ?. crank will be here tuesday, and now i don't have a 1st gear upgrade !..sigh, this is what i get for working long hours.

i will need the long studs out of it..as you know..new cylinders do not come with them, so i'll have to take them out, then the cylinder is yers !.

correct on gear dogs. went with new cylinder because this old one has already been bored twice, piston is .50 right now. i'm not saving it, you can have it if you want it ?.

yeah..i'll just have to wait until i can get it back in the shop, tear the front cover back off, and see what is wrong if anything ?, i just know something is not right with the clutch.

you prob will not find a manaul for such a late model here, this prob will be a dealer item ?, or look on ebay ?.

update: finally got the chance to drive this '02 trx450fm out of the shop, but with problems !. for some reason or another, the clutch adjustment is not working right ?, the center bolt will not turn easy, not sure what is going on with this ?. but odd's are, i will have to pull her back into the shop, get the front cover back off, and have a look to see what is going on ?. i used the old clutch parts, i may end up just ordering both clutch parts, replace them both while i am in there. i did get the adjustment adjusted in order to back her out, park her under my carport out of the rain/weather for the time being. i have this '06 trx500fm engine in my shop right now, all torn down. soo..i'll get this '02 trx450fm fixed later on, its still cold here, so she's not in a hurry to do any rides right now..lol. it will just have to wait until i get it back into the shop. but before i tear the front cover off, i'll ride it up and down my street, see if the clutch gets easier to adjust...and shifts.

@jeepwm69 , first gear was the upgraded gear set, no need to replace it, it looked to be in great shape. i guess honda already installed the upgraded gear set in '06 ?..not sure ?, but i did check the gear set, everything looked great.

update: just placed two orders for parts. one order is from rmatv: oem cylinder, oem cam chain, all oem gaskets, oem oil temp switch. oem head gasket, oem rocker box gasket, all this came to $ 528.63. parts from ebay : '' hot rods '' complete engine rebuild kit, comes with crank, crank bearings, some gaskets, oil seals, piston, piston rings, wrist pin, wrist pin c-clips, all this came to $ 644.96 with taxes. his budget ( that we talked about ) was $ 2,200.00 in parts and labor. i'm charging him $ 1,000.00 to pull motor, split motor, clean engine cases, put all back together, install engine back in frame. he's good with all this. hardest part out of all this is waiting on parts !..lol.

only way we will get out of this poor stuff they make and sell today..IS TO STOP BUYING CHINA JUNK !. and as everyone already knows..its all made in china now !.

This arrived this evening, as you can see in one of the pics, some good ole back woods red rtv sealant was used as a base gasket on the cylinder..DO NOT DO THIS...EVER !!!. engine is out, split, cleaned the cases up a tad. few broken rings ( i think anyway ? ) were in the bottom end. piston is .50, this tells me it was sunk more than once, some one thought it would be ok just to replace the top end ?..NO..YOU CAN NOT DO THIS !!. top of rod is bad, will replace it with a complete lower engine, gasket kit from hot rods. gonna go with oem cylinder, along with a few other oem parts from rmatv. last pic is the oil filter pick up screen, notice anything wrong in the pic ?..lol.

yeah..i'll go with the upgrade when i go to put it back together...it's an '06, maybe they changed the gear already ?..wont know until i get it apart.

going out on a limb here, the gears you got, and the old gear ( some one did not match them right ) does not match. the main shaft, and counter shaft are splinned differently. the old gear you took out, is not the correct gear, all these gears have a square spline, not v shapped on the main shaft. # 1 above ^^..is the main shaft, it must match # 11, as both are splinned correctly. in your pic above ^^, the gear on the right does not match the splines for # 1 main shaft. who ever has been inside this engine ?, did not put it back together the right way..lol.

both wires have a rubber plug around them, each one has to slide into the plastic cover. one cable comes up, other goes down. but to answer yer question, its not alot of space inside the cubby hole to pack all the cable down inside there. and what the heck is up with where you got the battery placed in that one pic ?, thats not oem for sure !..lol.

Well crap, as i figured, stepping away from this project was a bad idea. come to find out, i needed the rear lights cleaned, new bulbs installed ( have them ), lower skid plate cleaned and painted as well as the rear rack painted. got the rear rack painted, not installed yet. lower skid plate cleaned, painted, installed. in the process of cleaning the rear tail lights up, got to wait until i get my parts washer solution from tractor supply today. should have this 450 done before friday evening for sure ( i hope ?..lol ). small things always takes time to clean, paint, install. will get pic's when its all done.

Ok, been off this project for awhile, i've got another project hitting my yard friday ?, '06 trx500fm engine rebuild. so, time to get my hands back on this trx450fm, get the rear rack painted, installed, seat on, and get her out of my shop to make room for this trx500fm coming in. owner sank it, wants me to rebuild the engine. i told him 1k to pull motor, clean it all out, rebuild it with all new cam chain, oil seals, gaskets, back in and running for my labor, plus what ever parts cost ?. i explained to him i do not know what the damage is until i tear motor out, and go through it piece by piece, he agreed my asking price is very fair on labor. not to mention, honda will not touch anything older than 10 yrs old ?!. so, he seems to be a happy camper for my fee. he also knows my work speaks for itself from word of mouth that has been spread around. i've got to make a few trips to two different tractor supply stores to refresh my parts cleaning solution as neither store carries it in stock ?..thanks to you know who !..lol. i'll post some pic's of this trx450fm once i get it all finished, and out of my shop. gonna head out there right now, get started, as my shop is a mess, need to get this done, then prep my shop for this trx500fm project, hang tight outlaws..will get this trx450fm done !.