shadetree

have you checked the timing by any chance ??.

just a fyi, this final shaft also filts more than yer model, it covers a crap load of the trx420's, as well as the trx520's, and other trx500's, sooo..when doing a search ?, check to see if anyone has a final shaft listed for any of these models ?.

wow..thats a first, i've never seen a stud break off of the star wheel in all my 30 yrs of working on honda atvs. you do not need to remove the change clutch in order to replace or remove parts, if my memory is still worth a crap ?..lol, you should be able to change out that star wheel without doing any other work anywhere else on the engine. it would be easier to remove the change clutch for easier work area though. which means the centrifugal clutch has to come out, then the change clutch, both clutches use a 27mm right handed threaded nut.

take my advice, STAY FAR FAR AWAY FROM THIS MODEL !.

'01-'98 450's used a speed sensor, no gear position display. then from '02-'04 they just used speed sensors as far as i know. my '03 450fm only has speed on display.

going out on a limb here, my mind tells me dirty fuel injector ?, or maybe not enough fuel reaching throttle body ?. yes..i read where you said the fuel pump was replaced ^^ , but this does not mean fuel is reaching the pump, then to throttle body. also, i do not recall if these models have a bank angle sensor or not ?, its posb it is bad if this does in fact have a bank angle sensor. i still think this is a fuel delivery issue myself. somewhere on this atv is a fuel pump relay, it too can be bad.

welcome to the forums. you are in great hands here for that 450 !.

@bar777 , please do not post phone numbers in open forum. i deleted your number for safety's sake :-).

yeah, been working on my cabin lately, now i'm putting in a new driveway to it. should get gravel this saturday, then should be done ?!.

in the past, i made one work with super gluing the post back together.

rocky mountain atv has oem seat, just checked, $ 101.31, 10+ in stock as of this post.

is it just the outer cover ?, or the lcd screen under it ?, if its just the outer cover ?, they are cheap to replace.

rocky mountain atv sells honda parts cheaper than partzilla.

lucky for us, all boots that screw into the spark plug coil wire will interchange between all honda's.

run some wires straight to the fuel pump from the battery, 12 vdc, if the pump works by doing this ?, then the pump is good, and this will tell you its the fuel cut-off relay that is bad. blue wire is hot, green is ground/neg. DO NOT RUN THE PUMP DRY !!!.

from what i've read ( and understood ) in the honda service manual, the fan control unit DOES in fact protect the c.d.i. in an over heat , if the fan control unit fails to turn the fan on to cool the engine, it's supposed to cut power to c.d.i. ?, maybe i read it wrong ?.

update: ok outlaws, i am nearing the finish line !!. i got a lot of little things completed these last few day's, all windows are trimmed out, entry door floor has been fixed up with left over flooring from bedroom, all ac outlets installed, installed an exhaust fan on front porch, but i did not get a pic of it ( i'll get one of it here soon ). all i like now is shampooing the carpet in main room, some cleaning (dusting is more like it ), empty out the storage shed, and i should have everything done ?. taking today off, i'll head back down there sunday. here is a few progress pic's of my recent work.

@Popa Fry just because you get it fixed ?..DOES NOT MEAN YOU ARE NOT WELCOEM TO HANG HERE !...LOL. stick around...we love to talk about other things besides atvs.

'' not running for about a year after the motor went south from no oil '' this right here tells me the friction disk are stuck together !!. anytime they sit for a long time ?, the disk stick together..in this case, to the metal disk.

anytime it '' jumps '' when you go into a gear ?..THIS MEANS THE CLUTCH IS NOT ADJUSTED RIGHT !. or..the friction disk are stuck on one or some of the disk ?.

ok, let's break this down. ask yourself, was it shifting and moving great before you tore into it to change the one-way clutch bearing ?, or was it doing the same thing when you tore into it ?. i always back track on issues when i work on something, and then find out something changed when i fixed that problem ?!. this means..i did something different when i was putting it back together ?, or..the problem was always there..but it just did not show itself until i fixed the first problem ?. so in this case, if the shifting was good before you tore into it ?, then you either did not put it back together and adjust it correctly ?, or..its something else that is making it not shift right.

my money say's you do not have the clutch adjusted right ?, or the change clutch friction disk are sticking ?.

again, either bad reg/rec, or bad stator. which one ?..i can't answer that. if i was working on it, i'd look for a oem used parts from power sports nation, they stand behind their parts.

thank you !,i have seen a few c.d.i's do this..as well as reg/rec or stator fail when hot ?, mostly the c.d.i's do this. also.., i agree with jeep, a bad spark plug coil will do this.

the video of the corroded carb bowl ^^^ ?, i'll bank all my money that carb bowl had reg fuel sit in it for a very long time..and after so long, it turns ( collects water ) to that white junk. i have seen it many...MANY times in my 30 yrs of working on small engines. IT'S NOT THE FUEL DOING IT !!..ITS FROM SITTING FOR A VERY LONG TIME !!!. do as you wish..put non-ethy in yer tank..or follow the simple rules of when to run it, or how to drain it..either way..i am not buying into which fuel is best. p.s. DO YOU REALLY THINK EVERYONE ON FLUTUBE TELLS AN HONEST STORY ??..lol.