jstatham

23 hours ago, jeepwm69 said:

I'd look for a 98-01  Front driveshaft is the same, rear swingarm is the same, so should bolt right in, and the suspension on the 450's sits a little higher.

You are talking 400 and not 450 correct?

OK I have been trying to figure out what machine will work for a motor swap.  I have looked all the diagrams and came up with the part numbers for the frames and the front shaft.  It looks like my best bet would be a 1995-2003 Foreman 400.  Does anyone know if the 450 Frames are really that much different and would the 400 motor work?  Mine is a 1999 Foreman 400. 

1995-1998 Foreman 400 Frame
50100-HM7-610
50100-HM7-611 
50100-HM7-70096 

1999-2003 Foreman 400 Frame
50100-HM7-A10 
50100-HM7-A30
50100-HM7-A40

1998-2001 Foreman 450 Frame
50100-HN0-306 
50100-HN0-A70

2002-2004 Foreman 450 Frame
50100-HN0-670

1995-1998 Foreman 400 Front Drive Shaft
40400-HM7-A00

1999-2003 Foreman 400 Front Drive Shaft
40400-HM7-A00

1998-2001 Foreman 450 Front Drive Shaft
40400-HN0-A00

2002-2004 Foreman 450 Front Drive Shaft
40400-HN0-670

Well today was productive. What I realized Friday the original harness was still in the machine the previous owner had the hacked up harness hooked up to the front. I guess for testing purposes. The coil was all that was wrong.  Once I got it running with the hacked up harness I unplugged all that mess and hooked up the original harness and had it fired up in about 15 minutes.  I even let my daughter take it for a quick spin. The motor sounds ok but the machine still needs a ton of parts to bring it back looking good. I am going to keep my eye out for another machine with a blown motor and make a good looking machine.     @shadetree I did fix the tread on the other machine. Thanks again for everyone help. Sorry I kept posting the original video. I was doing it from my phone and didn’t realize.  More to come with this one. 
 

10 minutes ago, jeepwm69 said:

The 02-04 450 had a slightly shorter output shaft to account for the selectable front diff.

 

I know the bottom cases are the same, and the top ends are interchangeable.  
 

You need to look at the output shaft on the engine from the pre 02 450 and the 400s and see if they’re the same.  If so, it will likely bolt in.

 

I haven’t ever done that swap so can’t say for sure

Thanks jeep. My plan today is to drive it a little up and down the driveway before I say it’s good. Do you know if the 400 motor will fit in the 300 frame?
 

Hello everyone. I have been fighting this POS all week. I’m not expert in wiring but everything is cut and hacked up like crazy. Would I be smarter to just take the engine off and set it beside my working one and hook up to its wiring? if it’s compatible? Here is a video I made tonight. If you can’t tell I’m beyond frustrated. This thing is a 1999 I believe Forman 400 and I have a working 1996 Foreman 400. Does anyone have a spare harness I could rent to test it? None of them are electric shift.

Well she is alive and actually sounds good.  I think I am going to look for a 400 or 450 with a blown motor and swap it over. Are all the years from 1996-2003 compatible for an engine swap? If not what do I need to look for?  This bike needs way too many parts to try and fix it up and I don’t want to drop that much in it. Also I think I fixed the valve cover gasket on my other 400 with some bigger bolts. Fingers crossed. 
 

Hello everyone. I have been fighting this POS all week. I’m not expert in wiring but everything is cut and hacked up like crazy. Would I be smarter to just take the engine off and set it beside my working one and hook up to its wiring? if it’s compatible? Here is a video I made tonight. If you can’t tell I’m beyond frustrated. This thing is a 1999 I believe Forman 400 and I have a working 1996 Foreman 400. Does anyone have a spare harness I could rent to test it? None of them are electric shift.

Do they still look wrong?
 

Hello everyone. I have been fighting this POS all week. I’m not expert in wiring but everything is cut and hacked up like crazy. Would I be smarter to just take the engine off and set it beside my working one and hook up to its wiring? if it’s compatible? Here is a video I made tonight. If you can’t tell I’m beyond frustrated. This thing is a 1999 I believe Forman 400 and I have a working 1996 Foreman 400. Does anyone have a spare harness I could rent to test it? None of them are electric shift.

ok I will check it out.
 

Hello everyone. I have been fighting this POS all week. I’m not expert in wiring but everything is cut and hacked up like crazy. Would I be smarter to just take the engine off and set it beside my working one and hook up to its wiring? if it’s compatible? Here is a video I made tonight. If you can’t tell I’m beyond frustrated. This thing is a 1999 I believe Forman 400 and I have a working 1996 Foreman 400. Does anyone have a spare harness I could rent to test it? None of them are electric shift.

11 hours ago, shadetree said:

dang it..i had a book typed out, and the web site ate it ?... you better start with a good harness..that one is trash. a pic of a before and after trx400fw i did a few yrs ago. wanna do it right ?..you better spend the money..it wont be cheap !..lol.

Thanks Shade Tree that bike looks sweet.  I rebuilt one last year for my daughter and learned the hard way on the cheap parts.  I'll will let you know what happens.

Shade Tree all I am wanting to do is see if it runs before I tear it down but I did make a bunch of progress tonight.  I figured out there are actually 2 harness on the bike for some reason.  I have no clue why the previous owner did that.  Anyway I got it patched up enough to get it to turn over but I have no spark.  I have voltage going to the coil and nothing coming out the other end.  I checked the coil with the multimeter and no resistance on either terminal.  I didn't buy any of the Chinese junk it all came with the bike.  I learned the Chinese junk part lesson on my last build.  Anyway I am going to take the coil off the other bike this weekend and see what happens.  I am kind of on the fence with this bike do I fix it or use for parts.  If the motor cranks right up and sounds good I may fix if it smokes and knocks I am not going to waste my time. More to come this weekend.  Everyone be safe with the storms coming through.

I just had it hooked to a 10 amp battery charger.  I am just trying to get the Neutral lights to work so I can jump the start button that has been mutilated.   Once I get that working I will actually put a battery on it.

My father in law tried Helicoils and he put them in crooked are they are just spinning. If I am going to break it down I want to go back with something I know is going to work.  My good machine was a 400 but I put a 450 piston and jug and a 400 head on it. When I rebuilt it I changed the stickers to 450. 

Yes. My 400 needs a new head because the vale cover bolts are broken and leaks oil.  I don’t want to tear it down if the motor is good. If it’s good I will use as a spare. I have all the parts for this quad.

Hello everyone. I have been fighting this POS all week. I’m not expert in wiring but everything is cut and hacked up like crazy. Would I be smarter to just take the engine off and set it beside my working one and hook up to its wiring? if it’s compatible? Here is a video I made tonight. If you can’t tell I’m beyond frustrated. This thing is a 1999 I believe Forman 400 and I have a working 1996 Foreman 400. Does anyone have a spare harness I could rent to test it? None of them are electric shift.

I know the gear shift position sensor if different. I started tonight with a volt meter trying to get the light to come on when the switch it on and didn’t make it very far. The leads on my volt meter broke. Almost every wire has been hacked on. It’s a mess. I really don’t want to break down my good 1996 just to see if this motor is good. I’ll work on it this weekend when I am fresh and have some patience. After the day I had at work I didn’t need to mess with it. More to come.

Well I am finally getting back to this and thought I could use the wiring Harness from the 1996 but they are not the same from what I can tell.  I just want to see if this thing will run.  I was able to straight wire the starter and got it to turn over.  I am going to try and find he manual on this site. Does anyone have any experience doing this?      If the motor is good I am going to use for a spare if it is bad I need the head.

I just picked up yesterday a 1998 Foreman 400 that I am planning on using for parts. Before I tear down the engine I wanted to see if I could get it to run. Evidentially the starter button went out and the guy butchered the wiring harness trying to get it to run. My question what would be the easiest way to get it to run without taking my wiring harness off my good running machine. Is there a way I could park my good bike beside the bad and make some kind of jumper wires to use my good harness and CDI so I can get it to turn over and possibly crank. The pull start is removed but the starter is there. Any help would be greatly appreciated. I also got another 450 engine in the deal and would like to do the same with it.

I found a 400 complete for parts with an extra 450 engine.

8 minutes ago, shadetree said:

check powersports nation, see if they have a used 400 head ?, pretty sure the 450 head is the same as the 400 head ?.

No luck on power Sports nation.  The 450 head will give you less Compression.  Not the end of the world.

I have a 1996 Foreman 400 and need a head.  My bolts broke during restoration and leaking at the valve cover.  The Heli coil didn't work.  

I got it back together tonight and was able to bend the racks and pop the plastics back out. I did notice the frame was a little bent on the left side where the rack bolts up. I did notice the drivers side inner cv boot is ripped. Any recommendations on what boots to use? I can tell the steering is a little off but I am going to look at this weekend and see what I can figure out.

12 minutes ago, Fishfiles said:

This is the 400 head and the 450 head , all the valves ,springs , etc , etc , the only difference is the 450 has less compression than the 400

I actually have a 450 piston and running the 400 head. I am Actually looking for a new 400 head we broke some bolts and the helicoils aren’t holding and leaking oil. Do you have one for sale?

7 hours ago, shadetree said:

for parts, dont cheap out, buy oem ball joints from honda...NOT AMAZON OR EBAY !. looks like the tie rod is ok from what i see ?. as for the a-arms being bent ?, only way to tell for those is when it comes time to bolt it all back together..otherwise...its a gamble if they got bent or not ?. what year, make, model is this ??. i see foreman on the side panel, but the front bumper does not look like a trx450fm foreman to me. this a foreman rubi ?. prob is..because the trx450fm foreman's did not come with disk front brakes.

This is a 1996 Foreman 400 with the 450 head. I just completely refurbished it around Christmas and added the disc brakes. I am pretty sure you were helping me out then as well. Any advice for straightening out the rack.  I was going to use a chain or strap and hook it to the rack and a tree and use reverse and the throttle to bend it back.

Well my Daughter let her friend drive her ATV and she lost control and hit a tree. Luckily nobody was hurt.  It took me a while to get it loaded up on the trailer and get it back home.  I took the tire off and it looks like to me the only thing that got damaged was the front rack and up and lower ball joints.  Does anyone have any suggestions on how to tell if the control arms are bent and do you see anymore damage.  What ball joint would you recommend? The tie rod looks OK from what I can tell.  I am going to pressure wash tomorrow and try to tell what is going on.  Any help will be greatly appericated.

Hello everyone I finally got this thing going today. I put new Shindy rings, new timing chain,new clutches and she fired right up without smoking and sounding like a sewing machine. My daughter and I drove it about an hour and so far so good. She is so excited. It’s going to be warm for a few days and I am sure she is going to break it in.  Thanks again for all the help. Hopefully this time it will last a while.

Let's hope I don't run into anymore issues.  I am ready to be done with this!