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Kauaiian504

Honda trx450s/fm possibly 2003-2004

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So I have a 2003 (I believe) Honda trx450s. Bought from someone who potentially crashed it a few years ago. After his crash, the atv could only drive in reverse. He drove in reverse home, parked it and left it sitting for those years. I found oil in the air box and a loose foot shifter. I opened the crankcase and found 2 small silver tabs on the bottom. It looked like it sheared off something.  I repositioned the shifter. The plate cam clutch was off the clutch lever. We didn't get too far yet but the small pins look like that star shifter thing. I was hoping we could do the work without pulling the engine. Now the gears are totally in reverse. All the way down is Neutral. But when you try put it in reverse, it goes forward and the reverse light turns in. Then upshift (US) is neutral. Neutral light turns in. But then when you US again, you actually get all the 5 gears but all those gears are in reverse. The whole thing is backwards. Any thoughts? We think the oil in the air box was due to a rollover hopefully. Tested head and it fires up. Any assistance is appreciated...

IMG_20210216_093451837.jpg

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first question, did you pull the rear cover at all ?. if you did ?, then it sounds to me when you installed the rear cover, you did not line up the gear position switch correctly to the switch. by this, i mean the switch has a tang on the end of it, this tang has a long end on one side, this long end must sit over the letter N stamped on top of the switch, once this is set right, you now can install the rear cover back on, all while lining the tang back into the end of the shift drum slot.

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I would guess #31 in this print -----  Could also be the sheered off tips the spring #15 image.png

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Welcome to the forum. Are you "bench testing" these gears for the reverse drive results? Did you only pull the front crankcase cover or both? Need to know the location you found those pieces to narrow it down.

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3 hours ago, Goober said:

Looks like shift fork bases might be broken off.

02643A9B-051E-498F-AFC7-D57272463E37.jpeg

That's what I thought but it shifts fine. I only took the front cover off. I pulled the pull start and the gears go the correct direction. I guess since there's an automatic clutch, hand turning the wheels wasn't working. But it goes the correct direction. Those pins were found in the front case on the bottom. I was thinking, it looks like the case material but haven't put it next to a magnet yet to find out. 

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please post a full pic of your atv, i would like to see what it looks like, thank's !.

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10 hours ago, Kauaiian504 said:

That's what I thought but it shifts fine. I only took the front cover off. I pulled the pull start and the gears go the correct direction. I guess since there's an automatic clutch, hand turning the wheels wasn't working. But it goes the correct direction. Those pins were found in the front case on the bottom. I was thinking, it looks like the case material but haven't put it next to a magnet yet to find out. 

 

 

Drivers side, middle or passenger side of the motor? They look too big to be from anything with the shifting star (#6 in fishes reply above) yet too small to be from anything else. Looking at my hand and knowing we most likely have different size of hands it's hard o judge the exact size of the pieces but I have a general idea. I'm not thinking of anything though that would be roughly that size. Knowing if they are aluminum or metal might help as well.

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Also, only the right side 4wd works. The left side is stiff. I just repacked the grease. I readjusted the cv joint and it worked for another min but when I switched it back to 2wd and back to 4wd it wouldn't work. Any ideas? 

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2 hours ago, Kauaiian504 said:

Also, only the right side 4wd works. The left side is stiff. I just repacked the grease. I readjusted the cv joint and it worked for another min but when I switched it back to 2wd and back to 4wd it wouldn't work. Any ideas? 

lack of front diff gear oil ?, or the front diff inside at the clutch/gears needs looking at ?.

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3 hours ago, Kauaiian504 said:

Also, only the right side 4wd works. The left side is stiff. I just repacked the grease. I readjusted the cv joint and it worked for another min but when I switched it back to 2wd and back to 4wd it wouldn't work. Any ideas? 

Not saying you don't have a problem , but watch it closer next time you ride  , Honda 450  is  a limited slip front end , sometimes the traction will shift from one side to the other and some times one wheel will not turn ------ I done a trick to my front diff , added 2 more coned springs , one to each side  ,  makes it grab better but it is still not a true locker 

Seems if that wheel is dead , if you were to jack it off the ground and spin it , you might hear or feel something going on 

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Kauaiian504 , that 504 wouldn't be an area code , cause I am originally  from the 504 !!! LOL 

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Do those two pieces  look like they might have been one piece at one time and sheered  ? Do they fit together in the middle ? 

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image.png

 

Could it  be a roller out of the bearing number #27 --- did you try a magnet on those pieces to see if it is steel or aluminum ------  throw enough of stuff against the wall and something might stick 

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On 3/3/2021 at 10:19 AM, Fishfiles said:

image.png

 

Could it  be a roller out of the bearing number #27 --- did you try a magnet on those pieces to see if it is steel or aluminum ------  throw enough of stuff against the wall and something might stick 

 

THe rollers in number 27 are more like a 1/16" in dia. 

 

Feels like a game show....'name that debris'!

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