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.