jstatham

Hello everyone. I am in the process of rebuilding a 1996 Foreman 400. When it was parked about 15 years ago it was smoking like a freight train so I knew it needed new rings. I bought a 450 top end kit off ebay. I installed in a few month ago and fired it up for about a minute and everything seemed fine. I then tore the entire thing down to just the engine and the frame. I have been redoing the brakes,tires,paint,carb, etc. Today I got it but back together enough to fire it up. I figured I would let it idle for about 15 minutes then turn it off and change the oil and filter. In this process I discovered the new top end it cracked. I have oil seeping out between the fins. Is there something I did wrong or did the cheap ebay kit have a bad casting. What do I do now? Have the OE bored out? Try another ebay kit? Anyone with experience I would love some advice. Here is the kit I bought. https://www.ebay.com/itm/Honda-Foreman-450-Top-End-Rebuild-Kit-Cylinder-Piston-Gaskets-Std-90mm-1998-2004-/363223986276?mkcid=16&mkevt=1&_trksid=p2349624.m46890.l49286&mkrid=711-127632-2357-0 Here are a few pictures of the leak. https://youtu.be/-vkzcF9gLgg Any help will be greatly appericated.

Thanks. I just got back from the tire store. I got new tires and wheels and stuck with the 25. I didn't think a few inches was worth the money. I have the bike completely tore down and working on painting/lift,brakes and everything else.

On another questions I just bought a 2 inch lift and wonder what size tires you would recommend? I current have 25x8x12 in the front and 25x10x12 in the rear. I was thinking of going with 26 or 27 if they are in stock. Any thoughts?

Thanks for the info. I have some decisions to make. I have about 1500 to spend on this project. I need new tires and the plastics are pretty rough and the front rack is gone. I know I am going to do the front brakes to disc for sure not sure on the rear. I just took the plastics off and plan on pressure washing and breaking down the front and rear brakes tomorrow.

Awesome thanks for the info. Where are you located? What do you think the total cost for both front and rear brakes? Also does Super ATV still give the discount?

I have googled and googled and read and watched until I am tired of looking. I am looking with someone from experience with upgrading the Foreman 400 to Front and rear disc. I am looking at the super ATV for the rear and see all kinds of issues and found someone on youtube who used a SnowMobile caliper on the super ATV kit and it works awesome. I am trying to figure out is there a way to upgrade to rear disc and adding a master cylinder and not losing reverse on the handlebar. Does anyone know of a left handled master cylinder that will work with reverse? Or should I just bypass the reverse and not worry about it. I am rebuilding a 1995 Foreman 400 my father in law gave my daughter. I just put a 450 top end on it and jetted the carb. I am now working on cosmetics and safety. So any help would be greatly appreciated.