Gus.Cheese 2 Posted January 15, 2021 I’m only days out from pulling the motor from my 07 TRX500FM. My first gear is toast. Any advice or heads up you all can give me? What should I watch out for? I’ve fixed a Kawasaki transmission so I’m assuming Honda will be easier. 1 Share this post Link to post Share on other sites
jeepwm69 7,749 Posted January 15, 2021 If you've ever been in an engine it's not too bad. I've done a bunch of these 500's, so just take pics as you go, and if you have a question, stop, post pics, and ask. When you get ready to split cases, set the engine with the flywheel down, and pull the front crankcase 1/2 off, and first gear is right on top, so if you're careful you don't even have to pull the transmission out. You can leave the flywheel on since you're not pulling the crank too. If you google "420 crank youtube" there's a good 4 part video showing an 07 420 Rancher engine teardown, which is very similar to your 07 500 motor. You can download the factory service manual in the tool bar at the top of this forum too. Welcome aboard! 5 Share this post Link to post Share on other sites
sled_22 845 Posted January 20, 2021 One thing is for certain, you’ll never know what you’re going to find until you open it up. Mine quad worked in every gear but first but I also had all the splines wore of the primary drive as well as a few teeth in the first gear. Lots of shrapnel means lots of cleaning. be prepared to take it all apart and thoroughly clean all the bearings and each part meticulously. Don’t forget to flush the oil cooler and make sure you don’t have a stripped oil plug while you have it all apart. don’t be afraid to take pictures and ask question. You’re not the first to rip this engine down on this site. good luck and keep us posted. 1 Share this post Link to post Share on other sites
87Iroc 344 Posted January 24, 2021 Good luck! I had never been inside a ATV engine until this past summer. Service manual is king and as you take it apart make sure you take pics and lay it out in order. Also, one key thing Shadetree told me as I tore it down is 'the oil holes in the bushings must line up' when you put it back togehter. I'm not sure if yours has that...but it was important on my 450 to ensure oil got where it needed to be. 2 Share this post Link to post Share on other sites
shadetree 5,970 Posted February 5, 2021 On 1/24/2021 at 3:52 PM, 87Iroc said: Good luck! I had never been inside a ATV engine until this past summer. Service manual is king and as you take it apart make sure you take pics and lay it out in order. Also, one key thing Shadetree told me as I tore it down is 'the oil holes in the bushings must line up' when you put it back togehter. I'm not sure if yours has that...but it was important on my 450 to ensure oil got where it needed to be. yeah...pretty much all honda's have those oil holes in the shafts. 2 Share this post Link to post Share on other sites
Gus.Cheese 2 Posted February 23, 2021 All you guys seem really knowledgeable, thank you! Does anyone recommend a seal kit for this job or does anyone have a list of part numbers? Share this post Link to post Share on other sites
87Iroc 344 Posted February 23, 2021 (edited) RockyMountainATV is your friend. Great parts break down. There's another one that has better parts interchanges...but I forgot the name as they are more expensive. I tried to not go super cheap on gaskets(shut up shade). Nakamura? Maybe is what I used for head gaskets. I think the full engine gasket kit I bought I paid like 80 bucks for to give you a price range. Also, for seals, I went with Honda seals. Not super expensive. The full gasket sets don't come with oil seals Edited February 23, 2021 by 87Iroc Share this post Link to post Share on other sites
sled_22 845 Posted February 23, 2021 (edited) I bought all my parts from Honda East. (honda east toledo) out of Ohio? i believe. They were quick shipping and very good to work with. Also, saying you found their name online in forums, they'll give you %10-15 off. I would order an engine rebuild "kit A" and "kit B". also, replace all the seals. Front and rear output shafts, footshift, reverse shaft, valve seals. Here's a list of things i bought. You might have to finetune some of the parts. Edited February 23, 2021 by sled_22 1 Share this post Link to post Share on other sites
sled_22 845 Posted February 23, 2021 Shoot, i cut the final cost off that clip, it was $208 before tax. So like %24 off or something. I would recommend them.https://www.hondaeasttoledo.com/ 1 Share this post Link to post Share on other sites
jeepwm69 7,749 Posted February 23, 2021 25 minutes ago, sled_22 said: I bought all my parts from Honda East. (honda east toledo) out of Ohio? i believe. They were quick shipping and very good to work with. Also, saying you found their name online in forums, they'll give you %10-15 off. I would order an engine rebuild "kit A" and "kit B". also, replace all the seals. Front and rear output shafts, footshift, reverse shaft, valve seals. Here's a list of things i bought. You might have to finetune some of the parts. Good list. Don't forget the crank seal behind the pull start assembly. 1 Share this post Link to post Share on other sites
