Jump to content
jeepwm69

05-11 Foreman 500 FM engine rebuild

Recommended Posts

On 3/21/2020 at 9:40 PM, Will said:

Is there one kit that has all the gaskets and seals I will need for this job.

Hi Will.  You the guy from over in North MS?

 

https://www.powersportsdiscount.com/oemparts/l/hon/5053de3af870021c54bddba3/2007-trx500fm-a-parts

 

There are the schematics for an 07 Footshift.

 

You can buy an aftermarket kit, but it's just as cheap to get the OEM seals and stuff, and you know the OEM stuff is good.

 

Top end gaskets

https://www.powersportsdiscount.com/oemparts/p/honda/06113-hp0-a00/gasket-sheet-kit-a

 

Bottom end gaskets (sometimes you can get away with not replacing the bottom end gaskets.  If it tears anywhere when you pull the motor apart, replace it.  Otherwise if you clean the mating surface you can usually get away with reusing them.

 

https://www.powersportsdiscount.com/oemparts/p/honda/06115-hp0-a00/gasket-sheet-kit-b

 

Crank seal and reverse seals are #19 and #18 here

 

https://www.powersportsdiscount.com/oemparts/a/hon/5053de3af870021c54bddbab/rear-crankcase-cover

 

Front and rear output seals are #6 and #7

 

https://www.powersportsdiscount.com/oemparts/a/hon/5053de3bf870021c54bddbb3/final-shaft

 

Shifter seal is #25

 

https://www.powersportsdiscount.com/oemparts/a/hon/5053de3bf870021c54bddbb2/gearshift-drum

 

I would also STRONGLY recommend you replace the 1st gear set.  Just ask @shadetree about having to tear a motor all the way back down to replace the defective gears that came in the 05-08 Foremans.

 

https://www.powersportsdiscount.com/oemparts/p/honda/06234-hp0-306/gear-set-low

 

If you do all of that with a new crank and top end, you shouldn't have any problems out of that engine for a long time.

Share this post


Link to post
Share on other sites
 
2 minutes ago, jeepwm69 said:

Hi Will.  You the guy from over in North MS?

 

https://www.powersportsdiscount.com/oemparts/l/hon/5053de3af870021c54bddba3/2007-trx500fm-a-parts

 

There are the schematics for an 07 Footshift.

 

You can buy an aftermarket kit, but it's just as cheap to get the OEM seals and stuff, and you know the OEM stuff is good.

 

Top end gaskets

https://www.powersportsdiscount.com/oemparts/p/honda/06113-hp0-a00/gasket-sheet-kit-a

 

Bottom end gaskets (sometimes you can get away with not replacing the bottom end gaskets.  If it tears anywhere when you pull the motor apart, replace it.  Otherwise if you clean the mating surface you can usually get away with reusing them.

 

https://www.powersportsdiscount.com/oemparts/p/honda/06115-hp0-a00/gasket-sheet-kit-b

 

Crank seal and reverse seals are #19 and #18 here

 

https://www.powersportsdiscount.com/oemparts/a/hon/5053de3af870021c54bddbab/rear-crankcase-cover

 

Front and rear output seals are #6 and #7

 

https://www.powersportsdiscount.com/oemparts/a/hon/5053de3bf870021c54bddbb3/final-shaft

 

Shifter seal is #25

 

https://www.powersportsdiscount.com/oemparts/a/hon/5053de3bf870021c54bddbb2/gearshift-drum

 

I would also STRONGLY recommend you replace the 1st gear set.  Just ask @shadetree about having to tear a motor all the way back down to replace the defective gears that came in the 05-08 Foremans.

 

https://www.powersportsdiscount.com/oemparts/p/honda/06234-hp0-306/gear-set-low

 

If you do all of that with a new crank and top end, you shouldn't have any problems out of that engine for a long time.

haha..yeah..just ask me how much i cried..having to tear a brand new motor all the freaking way back down, just to replace that stupid 1st gear set !!!..rofl.

Share this post


Link to post
Share on other sites
 

Yes I am the one for north Mississippi. Thanks for the help I’m sure I will have more questions when I start Reassembling  the engine 

  • Like 1

Share this post


Link to post
Share on other sites
 

If you get stuck ask questions.  I have a couple of these motors torn down now waiting on rebuilt cranks from Vince.

 

I'm on here during the day mostly.  Nights and weekends send me a message on bookface.

 

Take some pics and post as you go!  There is also a free factory service manual link at the top of the page (under service manuals) where you can download the factory service manual for free in PDF format.

 

  • Like 1

Share this post


Link to post
Share on other sites
 

Got up and did some work this morning early.  My cranks from Vince are supposed to come in today (once again, super fast turnaround).

 

Scraped all the old gasket bits off the center cases front and rear.

 

Got the rear crankcase half cleaned out, new shifter seal installed, shift spindle installed, and rear crank bearing pressed into place.

 

Got the front crankcase half cleaned out, new front output shaft installed.  Someone put TWO output shafts on this thing!  LOL. I guess when it started leaning they just knocked a new seal in on top of the old one!

 

Planning on getting up in the morning and putting in new crank and all the transmission gears etc, and then buttoning up the crankcases.

 

 

  • Like 1

Share this post


Link to post
Share on other sites
 

Maybe the drive shaft  has a seal lip ring wore  into it and why they doubled up on the seal ?? 

Share this post


Link to post
Share on other sites
 

I'll check it when I put it back together.  My guess is they couldn't get the old seal out so they just drove another one in on top of it.

Share this post


Link to post
Share on other sites
 

Double the seal, double the protection right?  lol If it was the front one I could see thought of mind as often as they leak.

Share this post


Link to post
Share on other sites
 

As expected, got my cranks in from Vince yesterday.  Excellent work as usual, and incredible turnaround time.

 

 

cranks.JPG

 

Got the cases thoroughly cleaned out.

 

case.JPG

 

case2.JPG

 

Got the crank pressed in.

 

crank.JPG

 

And here in orange shows the balancer and crank index marks that you line up when pressing the crank into the case.

 

crankmarks.jpg

 

Got the transmission parts cleaned up in my parts washer, and set aside to dry today.  Will get the transmission and shift shaft in tomorrow and button up the center, and hopefully have time to get some of the front and rear put back together.

 

I had to pull the rear cover back off of that ES motor I rebuilt last week.  I normally get them together, put oil in them, and then roll them front to back, side to side, and even upside down to coat everything in oil before I install the engine in the frame and crank it up.

 

This one had an oil leak on the alternator cover when I did my turning/sitting/rolling (I will leave it face down for a bit to soak clutches, and then do the same on the rear to check for leaks).  With these 500 motors more often than not the gaskets stay intact when you tear the motor down, and can be reused without leaking, but on that ES motor the alternator gasket was seeping oil so I pulled it back off this morning, cleaned up the surfaces, and put in a new gasket, so that took the rest of my time today.  Got it buttoned back up and had to call it a morning.

Share this post


Link to post
Share on other sites
 

This morning I got the transmission reinstalled, shift shaft in place, and got the center cases bolted back together

 

Transmission laid out after a good bath in the parts washer.  If you lift the gear assemblies out from the bottom you can clean them good while holding the assemblies together.

tranny.JPG

Have to put these two side by side and lower them in at the same time.  I little tricky but not bad.  Make sure you get the thrust washer on the back of the left cluster, and there's another on top of the top gear on the right cluster (which is a new, updated 1st gear)

trannyinstall.JPG

How you have to pull first gear off the right cluster, to make room to put the idler gearset in place,

trannyinstall2.JPG

Then replace first gear

trannyinstall3.JPG

 

Rear shift fork goes straight up into the left cluster, the center and front forks go into the right cluster.  Line the pegs up into the slots on the shift drum, and then slide the pin/shaft through the holes.

trannyshiftforks.JPG

 

Then I put in a new rear output and reverse seals, cleaned up the rear case covers, and installed the flywheel (shim and cage bearing on first, then the flywheel), reverse lockout, secondary gears (top has a spacer on the back, shim on the front), rear cover, starter gears (shim on the outside of the bottom gear), and then the stator cover.

 

I spent about 20 minutes looking for the stator cover bolts, couldn't find them, so I robbed the ones off another motor that's waiting to be rebuilt.  Later I realized that the 2007 bottom end that I did last week had been missing the stator cover when I got it.  I had an extra cover and stator on hand, but I hadn't ever had the bolts to hold it on.  Going to have to get some (4) 6mmx80 bolts for the rear cover.  Odd size that i don't have in my shoebox full of 6mm Honda bolts.

  • Like 3

Share this post


Link to post
Share on other sites
 

Does anyone know what this is and where it goes. I get a little disorganized and have a few parts I can’t find a home for.

image.jpg

image.jpg

Share this post


Link to post
Share on other sites
 

That is the change clutch outer guide, it slides onto the mainshaft before you put the clutch basket and thrust washer on

Page 10-17 and 10-18 of Honda Service manual for the 05-11 Foreman 500

-or you just slide it into rear of change clutch basket before you put it on

Hope engine is not assembled at this time.....😃

 

Link to the Foreman 500 manuals, was not sure on your model or year but the Hondas are generally the same for that particular part

https://drive.google.com/drive/folders/1QvEKFzoIUuZ809T18CwVIDToUJfelcG-

Edited by AKATV
  • Like 2

Share this post


Link to post
Share on other sites
 
 

I’m doing pretty well I think. I’ve got the crankcase back together and from the crankcase to the alternate back together. All I have left is the front of the engine.

  • Like 1

Share this post


Link to post
Share on other sites
 
 

Does anyone know what this thing is o think I came from the front of the engine 

image.jpg

Share this post


Link to post
Share on other sites
 

That part is the camshaft bearing retainer,

it uses a 12mm bolt and fits over the camshaft bearing and under the camshaft sprocket to keep the camshaft bearing in place

The notch on the rear fits into a raised area of same dimension cast into the engine case

its on page 8-21 of the service manual, bottom picture

IMG_5282.JPG

Edited by AKATV
  • Like 1

Share this post


Link to post
Share on other sites
 
7 minutes ago, AKATV said:

That part is the camshaft bearing retainer, it uses a 12mm bolt and fits over the camshaft bearing and inder the camshaft sprocket to keepthe bearing in place

The notch on the rear fits into a raised area of same dimension cast into the engine case

its on page 8-21 of the service manual, bottom picture

IMG_5282.JPG

it does not keep a bearing in, it keeps the cam in place as far as i know ? :-).

Share this post


Link to post
Share on other sites
 

It holds the edge of the camshaft bearing into the bearing cavity

The bearing is actually part the camshaft so thy are one and the same

so, yep, the retainer keeps the bearing/camshaft in place ☺️

IMG_5283.JPG

Edited by AKATV

Share this post


Link to post
Share on other sites
 

Looks like a camshaft / assembly retainer plate to me !!! LOL 

 

Share this post


Link to post
Share on other sites
 
6 hours ago, AKATV said:

It holds the edge of the camshaft bearing into the bearing cavity

The bearing is actually part the camshaft so thy are one and the same

so, yep, the retainer keeps the bearing/camshaft in place ☺️

IMG_5283.JPG

agreed !, bearing is already on the cam, so yes..it retains both i guess you can say..lol.

Share this post


Link to post
Share on other sites
 

How about this one?  That will still work ok, right?  This was off the power steering 08 "parts bike" I bought a couple of weeks ago. 

 

In other news, I rode my buddy's bike down to check the river level yesterday.  Ran good, sounded like a sewing machine, then all of the sudden I got this horrible noise and it died.  I initially thought the engine locked up.  I checked the oil, which looked good, and then hit the starter and it started back up, but had a weird squealing noise.  Ran for a few seconds and died again. 

 

At that point I walked back to the house, got another wheeler, and towed it home.  By that time it had cooled off, and started up and was running quietly again. 

 

If I had to guess there's a galled bearing in there somewhere.  Going to have to tear it back down again and see what I find.

 

 

valve cover.jpg

Share this post


Link to post
Share on other sites
 
6 hours ago, jeepwm69 said:

How about this one?  That will still work ok, right?  This was off the power steering 08 "parts bike" I bought a couple of weeks ago. 

 

In other news, I rode my buddy's bike down to check the river level yesterday.  Ran good, sounded like a sewing machine, then all of the sudden I got this horrible noise and it died.  I initially thought the engine locked up.  I checked the oil, which looked good, and then hit the starter and it started back up, but had a weird squealing noise.  Ran for a few seconds and died again. 

 

At that point I walked back to the house, got another wheeler, and towed it home.  By that time it had cooled off, and started up and was running quietly again. 

 

If I had to guess there's a galled bearing in there somewhere.  Going to have to tear it back down again and see what I find.

 

 

valve cover.jpg

i would start with the oil pump, bearings don't lock up, cool that quick, and go again ?!, lack of oil is my guess.

Share this post


Link to post
Share on other sites
 

Well I'm going to have to tear it down regardless.  Just wondering what I should be looking for.

 

Oil light never came on, neither did the fan. 

Share this post


Link to post
Share on other sites
 
20 minutes ago, jeepwm69 said:

Well I'm going to have to tear it down regardless.  Just wondering what I should be looking for.

 

Oil light never came on, neither did the fan. 

if the oil temp sensor is not good ?, the fan will never come on. you can check the fan by turning key on, grounding the oil temp wire to engine, fan should come on when you do this. does not rule out a bad oil temp sensor though ?.

Share this post


Link to post
Share on other sites
 

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now

×
×
  • Create New...