sled_22

Out of curiosity, what's the advantage of having the front jacked up (electronic 4x4) as well as it being in gear (resistance to find slop)?

No lift. Machine is new to me, 2300 miles, 600 hours. I did a complete tear down and replaced 1st gear. It does have 27" vampires and 26" IPTs in the front. New tires are in the works as I don't need that aggressive of a tire for a what I do but figured is relevant to define as there's probably extra stress on the rear end. I'll probably get it on jack stands this week and see if i can't get the axle out and inspect those splines as I think that'll be the easiest to start. I know the rear shocks are pretty soft and i'm sure the machine didn't get any love in the swingarm dept either so those will be checked as well.

That worked well for me... you don't even need to remove the fan either, i just unbolted it with all the wiring/hoses still hooked up and just zip tied it as high in the frame as possible. It didn't take much to get the cover off. One thing I would suggest is to make sure you let the quad sit upright for a good bit to drain all the oil out of the cooler. and even then, when you unhook the cooler lines, it'd be good to have something to plug them. I was able to get the quad on the back rack by myself, but i used a cherry picker/engine hoist. If you don't have a hoist or lift, you'll probably need another guy or two to help you get it upright.

Can confirm there is a gasket on the front cover for the 500 foreman of that vintage. Just replaced all of those in my quad.

I posted on my phone and it autocorrected... when i lift and hold the shift lever, the machine slightly jumps when going from neutral to 1st but then does NOT move even when revving it up. even when i do it in 2nd 3rd and 4th, it completely disengages the clutch and no power is transferred to the wheels.

I don’t reread that, autocorrect. Machine will NOT move.

Tried your guts tests today. Whenever I hold the shift lever up, the clutch is fully engaged and machine will move or continue to move. Plates must not be sticking. And I believe adjustment is good? One thing I noticed is if I stop in 1st and want to go to neutral, it’s hard to down shift while it’s running, but if I shut it off, it drops into neutral instantly. It’s really not that bad, I’m just getting bit picky and want it to ride like new when the wife is on it.

thats how i set it the first and second go around taking the front cover off... 1/4 turn backwards which is why i ask if i should give it a little more... going to the woods with my kids tomorrow so i'll adjust before we go and see how it works. Thanks again for all the insight. I'm very well versed with a mechanical back field in engineering, design, and mechanics so none of this scares me. It's just learning the ins and outs of this machine. Can't wait for the fat second stimulas check so i can send it rocky mountain atv's way for some new tires.

Ran probably 15 miles tonight off and on. Everything worked as it should (other than the rear brakes). It does shift from 1st to neutral pretty hard while at a stop. Is this something that could be corrected by turning my clutch adjustment 1/8 turn counter clockwise???

Good to go. She’s a little faded but for 2100 miles and $1400 into it, I’m happier than a rat in a nut factory.

Used the engine hoist to put the back end way up in the air. Removed the pull start and the stator cover. I think something was bound but the thrust washer was in the right spot. The short shaft with the intermediate gears pulled out really hard. I think there was dirt or grime in there. Anyway, put it back together and the gears spun super easy. i got the flywheel back on and had to come in with the kids for some lunch. I’m 99% I’m good to go now.

I looked at that fich last night too... I think something has to be in there wrong. I didn't removed the flywheel when i replaced 1st gear so that starter clutch should be fine. If i get time this afternoon, i might loosen the top bolts to that cover and see if it frees anything up. If it does, i'm guessing that thrust washer is on the wrong side of the gear intermediate gear, even though I don't think it is. That or for some reason the starter clutch locked up on me while being out of the machine sitting on the bench. Thanks again for the replies, i'll report back when fixed.

Brand new gasket. I bought the gasket set b for the bottom end. I scraped and installed the new one. Yes TRX500FM 4x4

My connector terminal wasn't completely snapped together so i put dielectric grease on it and everything worked well. Next problem... Starter. It all worked when i took it apart.now when i try to start the machine, the start is clicking. it's getting power all the way to the starter. I know this by testing it without it bolted to the machine. So i must have put something together wrong? Should i be able to spin the mating gears inside the case which the starter meshes with? I can't budge those carefully prying with a small pry bar. I must have put something together wrong inside? i just don't want to use it and mess something up. is the starter maybe spinning the entire time the engine is running? urgh.

battery and dielectric grease are on the shopping list for tonight.

That's the one on the RH side of the air box just behind the frame rail? Might as well do that tonight before i get all the plastic back on it.

It is... i don't think i'd be able to do over 30 mph in 3rd gear. I know for a fact i shifted through all 5 gears. I'm not too bothered that 4-5 doesn't show except for the fact the motor was just completely tore down and I could have fixed it then... Now what try and remove the rear cover on the machine, blah....there's a good chance i hardly use 4 & 5.

I know ! well when i put it together it was in neutral and the position of the long side of the tee was pointed at the N.... and the display correctly shows R,N,1,2 & 3. could it be slightly off and not show 4 & 5? that doesn't make sense when the rest correctly show. Could it be faulty or broken perhaps? What does it hurt if it doesn't show 4 the or 5th?

Here's another question. I took it for a ride last night. Shifts through all the gears and runs pretty well. I'm happy about that. One thing i noticed, and it may not be a big deal and more of a voltage problem but the display didn't show which gear i was in for 4th or 5th gear. I know it shifted into each of those gears and out of them but it just wasn't displaying i was in any gear at that time. The battery in it is basically shot. I just have it in there for testing purposes. I'm getting a new one tonight and thus far have only started it with the pull cord.Could it simply be that it doesn't have enough voltage or something else? Thanks

Just finished up in the garage. Plates in the clutch were loose behind the springs. Evenly tightened then back up and put it all back together. Whalah, I have first gear again. Thanks Jeep

Did i pinch the clutch plate with the 4 springs when i put it back together? i had to take the springs off so i could fit my impact socket on. I am starting to think that's the problem.

I just rebuild the motor to replace a stripped out 1st gear. I just got it all back together in the frame. Starts right up and started in neutral which i had planned and hoped for. Problem: When I shift it into gear, the machine slightly lurches forward or reverse dependent upon which gear you ! it into. Then when giving it some throttle, the machine doesn't move. I can shift with display reading correctly, R, N, 1st, 2nd, and 3rd. It will not show display for 4th or 5th. Any ideas for what i did wrong? with the machine showing neutral, i can push it forward and reverse easily, you can tell when it's in gear when you try to push it. You can hear is shift through gears so i think that's all lined up correctly. Could I have done something wrong with the clutch? I can turn the adjustment screw counter clockwise until i feel resistance then go 1/4 turn clockwise and set the lock nut. But it still doesn't like it's doing anything. I know the clutch adjustment plate on the inside of the front cover was in it's slot and lined up with the adjustment screw when I put the cover on. Could have that move when setting it in place? WTF did i mess up on reassembly? Purrs like a kitten at idle and when throttled up but i don't want to mess anything up. THoughts or ideas before tear down again? Thanks, Sled.