2000 (i think) 400 ES 4x4 not working - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum

mypov · 11-25-2011, 10:30 PM

I do APOLOGIZE right now if this has been covered at noisome - I have and did search, but nothing came up - I searched before I registered though, maybe that was why nothing came up.

Question goes as follows...

I jacked up the quad, put it on stands, and applied throttle while holding on to the rear wheels - couldn't hold on to it, as both wheels spun (however the front wheels didn't really spin). Then I held on to one of the front wheels and applied throttle, I could hold on to the wheel while the other front wheel spun.

Then I took the bike out and drove it in the snow, I got stuck, noticed the back wheels spinning, but no power was being delivered to the front wheels.

Just wondering where I go from here. Should I take appart the front differential? to see if there is something wrong with the gears? I should note that the front drive shaft is spinning - when driving while not stuck.

Is this a common problem and fixable? I am a heavy equipment mechanic apprentice and have some mechanical knowledge of 4x4 systems (just not small engine setups).

Thanks for any help you can provide.

**toodeep** · 11-25-2011, 10:40 PM

Probably the front drive shaft/propeller shaft (motor to the differential) is striped and the coupler on the differential (it could be either one but that one is more common). Leave the rear end on the ground and jack up the front end and spin the front tires over by hand. Most likely that is here it is slipping.

Welcome BTW. Your going to want to find out if it's a 450ES when ordering parts.

rich450es · 11-25-2011, 11:29 PM

welcome to the forum !
yup toodeep got you pointed in the right direction !.....good luck !

mypov · 11-26-2011, 12:16 AM

right on!
Thanks guys, I'll jack er' up tomorrow and see how the front tires behave...Then I'll check the vin to see what year it is. I know for sure it is an Foreman ES - but yes, thank you indeed for pointing me in the right direction and the friendly welcome!

mypov · 12-03-2011, 03:49 PM

Jacked up the front of the bike, and was able to turn the right side tire - it felt as though it would grab, then release...was not able to turn the left tire. After closer inspection it looked as though the CV shaft had come loose from the front differential. I pushed the cv shaft in and found that the wheel was locked again and was not able to turn it by hand. Took the bike out for a test drive and the 4x4 worked for a while, but after a short period of time the 4x4 stopped working again.

I jacked the front up again and started taking it appart. I removed the lower ball joint (cracked the taper) and let it hang, then I removed the cv shaft from the hub, and noticed that the rear cv shaft boot (closest to the front diff) was deformed. After closer examination and removal of the cv boot, the shaft separated. I am not sure how the shaft is supposed to stay together, but the shaft has ball bearings retained in some sort of race which is attached to the end of the shaft...this fits into a cup which is then inserted into the front diff...It seems to me that either there is a malfunction with whatever holds the shaft together - or there is a malfunction with the retaining clip that holds the cup (and splines) in the front diff. There are balls missing from the race - I think there are supposed to be 5, but I found only 3 - don't know where they went, but they were not in the boot...weird.

Anybody have an idea of what I should do now?

rich450es · 12-03-2011, 04:00 PM

if the cv shaft keeps pulling out of the front diff the little clip at the end of shaft may be worn out or......the grove the the little clip fits into (in the front diff ) is worn out
also if its a es its a 450 1998 to 2004
here is a manual that you can download for free
https://rs575l33.rapidshare.com/#!do...9A260DDFA1|0|0

utterchaos · 12-03-2011, 04:02 PM

Welcome to the forum! Good luck with your bike. I hope the guys can help ya get going again

11-25-2011, 10:30 PM	#1 (permalink)
mypov Honda Rider Join Date: Nov 2011 Posts: 3	2000 (i think) 400 ES 4x4 not working I do APOLOGIZE right now if this has been covered at noisome - I have and did search, but nothing came up - I searched before I registered though, maybe that was why nothing came up. Question goes as follows... I jacked up the quad, put it on stands, and applied throttle while holding on to the rear wheels - couldn't hold on to it, as both wheels spun (however the front wheels didn't really spin). Then I held on to one of the front wheels and applied throttle, I could hold on to the wheel while the other front wheel spun. Then I took the bike out and drove it in the snow, I got stuck, noticed the back wheels spinning, but no power was being delivered to the front wheels. Just wondering where I go from here. Should I take appart the front differential? to see if there is something wrong with the gears? I should note that the front drive shaft is spinning - when driving while not stuck. Is this a common problem and fixable? I am a heavy equipment mechanic apprentice and have some mechanical knowledge of 4x4 systems (just not small engine setups). Thanks for any help you can provide.

11-25-2011, 11:29 PM	#3 (permalink)
rich450es Honda Red Wing Rider Join Date: Nov 2010 Location: ludlow,mass Posts: 10,524	welcome to the forum ! yup toodeep got you pointed in the right direction !.....good luck ! __________________ 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**

12-03-2011, 04:00 PM	#6 (permalink)
rich450es Honda Red Wing Rider Join Date: Nov 2010 Location: ludlow,mass Posts: 10,524	if the cv shaft keeps pulling out of the front diff the little clip at the end of shaft may be worn out or......the grove the the little clip fits into (in the front diff ) is worn out also if its a es its a 450 1998 to 2004 here is a manual that you can download for free https://rs575l33.rapidshare.com/#!do...9A260DDFA1\|0\|0 __________________ 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**

12-03-2011, 04:02 PM	#7 (permalink)
utterchaos Honda Addict Join Date: Nov 2011 Location: North Mississippi Posts: 217	Welcome to the forum! Good luck with your bike. I hope the guys can help ya get going again __________________ 2012 foreman 500 red (310 miles) Big gun exhaust moose back rest audiopipe tube ITP 14" 212 rims 28" zillas http://www.youtube.com/user/clintbwell83 (Lots of fun mud and riding vids on my tube) 2006 rancher 350 yellow (wifes bike) audiopipe tube itp106's w/ 26" mudlites --soon to trade for a 420 rancher-- “It is your attitude, not your aptitude, that determines your altitude.”

11-25-2011, 10:40 PM	#2 (permalink)
toodeep Administrator Join Date: Aug 2007 Location: south dakota Posts: 6,628	Probably the front drive shaft/propeller shaft (motor to the differential) is striped and the coupler on the differential (it could be either one but that one is more common). Leave the rear end on the ground and jack up the front end and spin the front tires over by hand. Most likely that is here it is slipping. Welcome BTW. Your going to want to find out if it's a 450ES when ordering parts.

11-26-2011, 12:16 AM	#4 (permalink)
mypov Honda Rider Join Date: Nov 2011 Posts: 3	right on! Thanks guys, I'll jack er' up tomorrow and see how the front tires behave...Then I'll check the vin to see what year it is. I know for sure it is an Foreman ES - but yes, thank you indeed for pointing me in the right direction and the friendly welcome!

12-03-2011, 03:49 PM	#5 (permalink)
mypov Honda Rider Join Date: Nov 2011 Posts: 3	Jacked up the front of the bike, and was able to turn the right side tire - it felt as though it would grab, then release...was not able to turn the left tire. After closer inspection it looked as though the CV shaft had come loose from the front differential. I pushed the cv shaft in and found that the wheel was locked again and was not able to turn it by hand. Took the bike out for a test drive and the 4x4 worked for a while, but after a short period of time the 4x4 stopped working again. I jacked the front up again and started taking it appart. I removed the lower ball joint (cracked the taper) and let it hang, then I removed the cv shaft from the hub, and noticed that the rear cv shaft boot (closest to the front diff) was deformed. After closer examination and removal of the cv boot, the shaft separated. I am not sure how the shaft is supposed to stay together, but the shaft has ball bearings retained in some sort of race which is attached to the end of the shaft...this fits into a cup which is then inserted into the front diff...It seems to me that either there is a malfunction with whatever holds the shaft together - or there is a malfunction with the retaining clip that holds the cup (and splines) in the front diff. There are balls missing from the race - I think there are supposed to be 5, but I found only 3 - don't know where they went, but they were not in the boot...weird. Anybody have an idea of what I should do now?

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