'96 Foreman 400 Issues! - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum

thetater11 · 10-14-2011, 11:54 AM

I finally got around to taring down my Foreman to do some maintenance since I bought it used. But there's a couple issues:

1. I drained the rear diff. and once I removed the check bolt out, about 2oz. of dirty water came out and that was it. So I filled it up with gear oil and a few minutes later, the gear oil started leaking out between the hub and shaft of the left (when looking at the ATV from the back) rear wheel. Is this cause I put too much oil? Or does it mean there's a bad seal somewhere? I also drained the front diff. and all that came out was very muddy oil, so I let it drain overnight and i'll refill it today.

2. I noticed my choke lever was stuck all the way to the right (when sitting on ATV) and wouldn't budge. So I pulled the carb out and when I unscrewed the SE valve nut to remove it, i unscrewed it all the way but it would not come out, so i kept trying to get it out and eventually it pulled loose...but the valve stayed in the carb and all I had left was the choke cable end in my hand. It's like the valve is cemented in the carb and will not budge. Any idea on how to fix this? Is this common? The carb is in pretty bad shape so I'll be ordering a new one. OEM wants $368.65 for a new one but I found them all over eBay for $130.

3. I removed the cylinder head cover and noticed that one of the bolts is black and not steel and clean like the others. When I put the cylinder head cover back on, I tightened too hard i guess for that one and the bolt snapped in two, but the threaded portion stayed in the hole. How do I get it out? I was thinking drill it out with a bit just smaller than the threads of the bolt hole and then put a new bolt in and it will just push the shavings of the old bolt into the hole? Or can I survive with just 3 bolts holding the cylinder head cover on?

Any help is greatly appreciated! Thanks!

**toodeep** · 10-14-2011, 01:31 PM

1. You have a seal out and possibly bearings. Remove the left outer axle housing (tube) and inspect it for any play in the differential bearings.

2. If your getting a new carb don't worry about it. The choke valve is most likely trash anyways so get a new one of those also.

3. Sometimes they will just spin back out with a pick. I weld on the broken bolt to build it up enough to use vise grips. An easy out is another option or left hand drill bit. Most likely it's going to leak a little oil with only 3 bolts.

thetater11 · 10-14-2011, 01:58 PM

Thanks for the insight, very helpful. Any idea on the best places to get a carb? Bikebandit.com has OEM ones for $368.65 but that's a lot of money. I've seen some on eBay for $130 but not sure what kind they are or if that's a reliable source for this type of thing? Any other good manufacturers that make them for a little less? Or maybe find a used one that's in decent shape?

thetater11 · 10-14-2011, 07:30 PM

Well I removed the left rear wheel and got to the axle nut and cannot get it off for the life of me. I used PB Blaster and all my strength but could not do it. Any ideas??. But...once I got the wheel off, I found out that I can move the left rear axle around quite a bit..I'd say about 1/2" or so in a circle...so I'm guessing the bearing is pretty bad. I also noticed that when I turn one of the rear wheels, they both spin together but when I look inside the rear diff, the gears are not spinning with the axle. I thought this would change if I put it in gear, but no...the rear axle spins but the rear diff gears don't move. Is this normal? Thanks!

rich450es · 10-14-2011, 07:39 PM

use a big pipe on the end of the ratchet to get the axle nut off
yup it sounds like the bearings in the rear end are shot!
that carb on e-bay will worke for you (there are a few people on the forum that run them )

thetater11 · 10-15-2011, 05:50 PM

Awesome, thanks! I just ordered a carb on eBay. One other thing I'm curious about are the rear tires...when I removed them, I noticed they're about 1/3 full of water. I know sometimes people put water in tractor tires and stuff for added weight but is this something you would do on an ATV? Or is this just from the ATV being ridden in water? What should I do about it? I'm not sure if the front tires have water in them or not cause I haven't taken them off yet.

rich450es · 10-15-2011, 06:31 PM

i would just take the water out (eather you or take it to a tire shop and have them break 1 bead and empty it) i dont think you need the extra weight!
did you order the new choke valve with the carb ?

lop3r1 · 10-15-2011, 06:59 PM

that broken bolt is going to be a booger if you don't have an extraction kit. it consists of left hand drill bits and extractors. the drill bits will occasionally bite hard enough to back the bolt out, but most likely, once you've drilled straight down the center, you'll have to use the extractor to free it. do not try the method that you mentioned...or you'll be drilling and re-tapping for a larger bolt, or have to install a heli-coil. there are specialty tools designed for your predicament. you'll need a center punch, also.

thetater11 · 10-16-2011, 04:37 PM

I haven't ordered a new choke valve yet. The carb said it comes with choke starter set and choke cable boot...does this mean I still need a choke valve? I was gonna wait till it got here to see what else I'll need.

thetater11 · 10-16-2011, 04:40 PM

Are CV boots pretty easy to replace? Both mine are split in two so just wondering how much work I'm looking at to get them off or what other things I should inspect since I'll be taking the front end down pretty much and might as well check everything out while I've got it in pieces.

10-14-2011, 11:54 AM	#1 (permalink)
thetater11 Honda Rider Join Date: Sep 2011 Location: Tampa, FL Posts: 39	'96 Foreman 400 Issues! I finally got around to taring down my Foreman to do some maintenance since I bought it used. But there's a couple issues: 1. I drained the rear diff. and once I removed the check bolt out, about 2oz. of dirty water came out and that was it. So I filled it up with gear oil and a few minutes later, the gear oil started leaking out between the hub and shaft of the left (when looking at the ATV from the back) rear wheel. Is this cause I put too much oil? Or does it mean there's a bad seal somewhere? I also drained the front diff. and all that came out was very muddy oil, so I let it drain overnight and i'll refill it today. 2. I noticed my choke lever was stuck all the way to the right (when sitting on ATV) and wouldn't budge. So I pulled the carb out and when I unscrewed the SE valve nut to remove it, i unscrewed it all the way but it would not come out, so i kept trying to get it out and eventually it pulled loose...but the valve stayed in the carb and all I had left was the choke cable end in my hand. It's like the valve is cemented in the carb and will not budge. Any idea on how to fix this? Is this common? The carb is in pretty bad shape so I'll be ordering a new one. OEM wants $368.65 for a new one but I found them all over eBay for $130. 3. I removed the cylinder head cover and noticed that one of the bolts is black and not steel and clean like the others. When I put the cylinder head cover back on, I tightened too hard i guess for that one and the bolt snapped in two, but the threaded portion stayed in the hole. How do I get it out? I was thinking drill it out with a bit just smaller than the threads of the bolt hole and then put a new bolt in and it will just push the shavings of the old bolt into the hole? Or can I survive with just 3 bolts holding the cylinder head cover on? Any help is greatly appreciated! Thanks!

10-14-2011, 07:39 PM	#5 (permalink)
rich450es Honda Red Wing Rider Join Date: Nov 2010 Location: ludlow,mass Posts: 10,524	use a big pipe on the end of the ratchet to get the axle nut off yup it sounds like the bearings in the rear end are shot! that carb on e-bay will worke for you (there are a few people on the forum that run them ) __________________ 2000 foreman 450 es-s the fking pig 14% 300 foretrax gear reduction 30in gorila silverbacks on C-5 wheels 2500lb warn winch superatv disk brake conversion kit 2in ssatv lift kit and progressive 512 shocks the original 4in PVC storage tube hurculined racks with rear cargo box czr loud exhaust , uni airfilter and drilled main jet foreman 450 parts for sale pm me for info**

10-15-2011, 06:31 PM	#7 (permalink)
rich450es Honda Red Wing Rider Join Date: Nov 2010 Location: ludlow,mass Posts: 10,524	i would just take the water out (eather you or take it to a tire shop and have them break 1 bead and empty it) i dont think you need the extra weight! did you order the new choke valve with the carb ? __________________ 2000 foreman 450 es-s the fking pig 14% 300 foretrax gear reduction 30in gorila silverbacks on C-5 wheels 2500lb warn winch superatv disk brake conversion kit 2in ssatv lift kit and progressive 512 shocks the original 4in PVC storage tube hurculined racks with rear cargo box czr loud exhaust , uni airfilter and drilled main jet foreman 450 parts for sale pm me for info**

10-15-2011, 06:59 PM	#8 (permalink)
lop3r1 Honda Red Wing Rider Join Date: Mar 2010 Location: gulfport, mississippi Posts: 810	that broken bolt is going to be a booger if you don't have an extraction kit. it consists of left hand drill bits and extractors. the drill bits will occasionally bite hard enough to back the bolt out, but most likely, once you've drilled straight down the center, you'll have to use the extractor to free it. do not try the method that you mentioned...or you'll be drilling and re-tapping for a larger bolt, or have to install a heli-coil. there are specialty tools designed for your predicament. you'll need a center punch, also. __________________ 07 foreman s camo 2" hl lift 1" hl wheel spacers 27" outlaws epi/hl outlaw clutch kit hmf utility, uni filter, dynojet kit 3000lb superwinch triangle snorkel kit herculiner on racks/front bumper custom front recovery point

10-14-2011, 01:31 PM	#2 (permalink)
toodeep Administrator Join Date: Aug 2007 Location: south dakota Posts: 6,628	1. You have a seal out and possibly bearings. Remove the left outer axle housing (tube) and inspect it for any play in the differential bearings. 2. If your getting a new carb don't worry about it. The choke valve is most likely trash anyways so get a new one of those also. 3. Sometimes they will just spin back out with a pick. I weld on the broken bolt to build it up enough to use vise grips. An easy out is another option or left hand drill bit. Most likely it's going to leak a little oil with only 3 bolts.

10-14-2011, 01:58 PM	#3 (permalink)
thetater11 Honda Rider Join Date: Sep 2011 Location: Tampa, FL Posts: 39	Thanks for the insight, very helpful. Any idea on the best places to get a carb? Bikebandit.com has OEM ones for $368.65 but that's a lot of money. I've seen some on eBay for $130 but not sure what kind they are or if that's a reliable source for this type of thing? Any other good manufacturers that make them for a little less? Or maybe find a used one that's in decent shape?

10-14-2011, 07:30 PM	#4 (permalink)
thetater11 Honda Rider Join Date: Sep 2011 Location: Tampa, FL Posts: 39	Well I removed the left rear wheel and got to the axle nut and cannot get it off for the life of me. I used PB Blaster and all my strength but could not do it. Any ideas??. But...once I got the wheel off, I found out that I can move the left rear axle around quite a bit..I'd say about 1/2" or so in a circle...so I'm guessing the bearing is pretty bad. I also noticed that when I turn one of the rear wheels, they both spin together but when I look inside the rear diff, the gears are not spinning with the axle. I thought this would change if I put it in gear, but no...the rear axle spins but the rear diff gears don't move. Is this normal? Thanks!

10-15-2011, 05:50 PM	#6 (permalink)
thetater11 Honda Rider Join Date: Sep 2011 Location: Tampa, FL Posts: 39	Awesome, thanks! I just ordered a carb on eBay. One other thing I'm curious about are the rear tires...when I removed them, I noticed they're about 1/3 full of water. I know sometimes people put water in tractor tires and stuff for added weight but is this something you would do on an ATV? Or is this just from the ATV being ridden in water? What should I do about it? I'm not sure if the front tires have water in them or not cause I haven't taken them off yet.

10-16-2011, 04:37 PM	#9 (permalink)
thetater11 Honda Rider Join Date: Sep 2011 Location: Tampa, FL Posts: 39	I haven't ordered a new choke valve yet. The carb said it comes with choke starter set and choke cable boot...does this mean I still need a choke valve? I was gonna wait till it got here to see what else I'll need.

10-16-2011, 04:40 PM	#10 (permalink)
thetater11 Honda Rider Join Date: Sep 2011 Location: Tampa, FL Posts: 39	Are CV boots pretty easy to replace? Both mine are split in two so just wondering how much work I'm looking at to get them off or what other things I should inspect since I'll be taking the front end down pretty much and might as well check everything out while I've got it in pieces.

Remove Advertisements Sponsored Links
Honda Foreman Forum Advertisement