jeepwm69

Shouldn't have to reset anything. Turning the key off and on is all it takes.

Oh I know the HOW, it's actually getting all that crap in there and getting the shift forks to stay in place while I slide that rod in that's the problem. I got clumsy hands! I also got it all in there and found a shim left over. Uh oh. It was the one that goes behind the bottom gear on the left side shaft. Had to take it all out again to get that shim in place.

Got this one back together this morning, adjusted valves, and probably gave myself a hernia carrying it out to my truck. Will get it back to the youngster in the next day or two to get it reinstalled.

Order a Cam Chain from G&H or ? Mine came pretty quick for the 450 I just got back together. I'm finally beating you on one! Of course, I've been working on this one since mid September!

I'd let it idle at night in the dark, see if the heater pipe glows red. That's a tell tale sign of a lean fuel condition.

Yeah, but if he's not getting any noise from the shift motor he has electrical/computer issues. Probably would be a good idea to pull the shift motor and verify that the gears under the shift motor are moving when he shifts using the foot shifter.

I have on backorder two right tank covers, adventure green, for a 2008 TRX500FM. $29.63 each. I placed that order on 1/17/23. They are still available to backorder. Current price is $866.95 at Partzilla. https://www.partzilla.com/product/honda/83550-HP0-B80ZA?ref=abd1ffd23bd6eefed0dd353fe901b0815ee20d0d

Interesting to note that while most foot shifts and ES's have the same transmissions in them, the 450s actually have different transmission gears between the two. The 450 ES transmission is designed to shift easier, but is not as durable as the 450 foot shift transmission. 350's, 420's, 500's the transmissions are the same whether ES or footshift. This is the 04 450ES engine I've been working on this week.

I highlighted the "seat bracket" in your old post, which is what I was referring to. As for the air filter cage.....YIKES. It's crazy how high some of these small bits are.

Agree with Shade. You need to check your current shift motor by jumping 12V to it. Did you read @retro's sticky on ES machines? Downloaded the free factory service manual from the "service manuals" link in the toolbar? You have a lot of wiring and a computer telling that shift motor when to shift. Bypass kits have become popular since they basically bypass the computer and angle sensor and just supply 12V to the shift motor. So you'll likely have to do a lot of troubleshooting to get it working in factory form, or get a bypass kit to just get it working. I'm sure there are some risks/drawbacks with the bypass system, but I don't tend to do much on ES machines so maybe Retro can chime in with some advice. All of that said, don't throw parts at it. You have shift buttons, wiring, a computer, and angle sensor that communicates with said computer, and a shift motor. That's the system. Troubleshoot the components instead of replacing.

I KNEW IT. That dang thing is always missing on a 450

Got down to 39 here last night. I was out in the shop early this morning and had to bundle up. Nothing like scraping 20+ year old gaskets with a razor blade in the cold!

I have two giant toolboxes. Both were walmart clearance items from back when the brickseek app worked and I'd chase walmart clearance items all over the place. The bottom cases were marked down to $79, and the top to $59. I did have to do some driving to get two bottoms and two tops, but it was worth it. These were made by Waterloo, and are really good quality toolboxes. I have parts only in one of them, and the other has tools everywhere except the bottom drawer, where I keep all my Honda nuts and bolts in plastic trays, separated by size. https://brickseek.com/walmart-inventory-checker?sku=696207319 https://brickseek.com/walmart-inventory-checker?sku=892612228 I did learn the hard way to not open more than a drawer or two at a time when the drawers are loaded with tools. Whole thing came over and luckily I wasn't under it. I have the heavy one full of tools bolted to the wall now!

Mine looks like an episode of hoarders. Can't find anything, one little path going through the middle, and it just keeps getting worse. I need a clean out BAD.

Sure! Your hunting buddy doesn't want it?