97 Foreman 400 - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum
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Old 09-09-2012, 03:04 PM   #1 (permalink)
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Default 97 Foreman 400

Whats up guys,
Just picked up a 97 foreman 400 4x4 this morning for $500. Plastics are really clean, seat has a small tear in it, and it starts and runs with the help of some starting fluid.

The big problems are, the guy pulled the front and rear drive shafts and diffs out. The rear axle, the splines are rusted and so are the splines in the rear diff. Haven't figured out whats wrong with the front parts yet.

My question is, how hard is it to rebuild these diffs? Or is it cheaper to buy a used one?

Also what are the tolerances for the valves?

I will be changing the oil, gas, plug, cleaning the carb, and doing valve adjustments while I wait for the parts to start showing up. I'll try to get some pics soon.
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Old 09-09-2012, 03:19 PM   #2 (permalink)
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to take the pinions out of the diffs you need a special socket but besides that there easy to rebuild if you have a manual ..... here is a thred with homemade honda tools and i use a steem rad valve to remove pinion nut
http://www.hondaforeman.com/144-how/...nda-tools.html

both the valves are set at .006 or .15mm
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Old 09-12-2012, 08:03 AM   #3 (permalink)
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Honda wants a lot of money for the new ring and pinion gears. I started searching ebay and found quite a few used diffs and axles. Is it worth buying used parts? The more I keep reading, the more it seems like the rear ends are a common problem for the older foremans.

Also, is there a cheaper way to add disc brakes on the front, other than buying a kit? I haven't got to mess with the bike much since I got it home because of work. But I was wondering if a set of foreman 500 spindles would work with the 500 disc brakes?

Thanks for info Rich, I didn't realize the valve tolerances were the same as my 500. Do you know where I could get a cheap shop manual for the 400 at?
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2011 Foreman 500S

High Lifter Signature Lift
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High Lifter Pull Starter Leak Shield
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Dynojet Jet Kit
2" Dual Snorkels w/ Rerouted Vent Lines
K&N Air Filter
HMF Utility Pipe
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High Lifter 29.5" Outlaw 2 Tires S/W
ITP 14" SS212 Black Wheels

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Old 09-12-2012, 08:56 AM   #4 (permalink)
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i belive if you can find a 05-11 foreman 500 parts bike (or parts off e bay) all the front diskbrakes will bolt right up to the 400 knuckle (i remember a guy on here did it from ebay parts and it was $160 )
as for buying a used diff of e bay ....its kinda a crap shoot ....i have bought diffs before of ebay and have had good luck
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Old 09-22-2012, 12:27 AM   #5 (permalink)
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Whats up guys, finally got some time to work on my $500 Foreman. Got some pics and my parts list got bigger.

I had to drain all the gas, pull the carb apart and cleaned it, adjusted the valves, and changed the plug.

The bike fired up with no smoke, but we're having carb problems. If you turn the choke off it dies, but half choke and it idles smooth with good throttle.

The parts I need are a front propeller shaft, front joint for propeller shaft, rear diff, rear axle, carb rebuild kit, and a fuel filter (was gummed up really bad) so far.
Attached Thumbnails
97 Foreman 400-hpim1924.jpg   97 Foreman 400-hpim1925.jpg   97 Foreman 400-hpim1928.jpg   97 Foreman 400-hpim1930.jpg  
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2011 Foreman 500S

High Lifter Signature Lift
High Lifter 1" Wheel Spacers
High Lifter Pull Starter Leak Shield
Turners Cycle HD U Joint
Turners Cycle Gear Reduction
Warn XT25 Winch
Dynojet Jet Kit
2" Dual Snorkels w/ Rerouted Vent Lines
K&N Air Filter
HMF Utility Pipe
EPI Clutch Kit
High Lifter 29.5" Outlaw 2 Tires S/W
ITP 14" SS212 Black Wheels

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Old 09-24-2012, 08:29 AM   #6 (permalink)
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Anybody know where I can get a good carb rebuild kit for this 400? I was going to a K&L kit from Rocky Mountain, but the reviews weren't so good?
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2011 Foreman 500S

High Lifter Signature Lift
High Lifter 1" Wheel Spacers
High Lifter Pull Starter Leak Shield
Turners Cycle HD U Joint
Turners Cycle Gear Reduction
Warn XT25 Winch
Dynojet Jet Kit
2" Dual Snorkels w/ Rerouted Vent Lines
K&N Air Filter
HMF Utility Pipe
EPI Clutch Kit
High Lifter 29.5" Outlaw 2 Tires S/W
ITP 14" SS212 Black Wheels

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Old 10-05-2012, 10:53 AM   #7 (permalink)
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I just got the foreman rolling around finally, but I'm still having some carb issues. It will start right up perfect on full choke, I actually let it idle on full and half choke for atleast 5 minutes so I could get the oil warm enough to change. When ever I shut the choke off all the way, it dies. The airbox is on, but the factory snorkel is off. So there is the hole in side of the airbox.

Is the quad getting to much air to run without the choke? It starts to pop before it dies and I just rebuilt the carb using a kit from moose.
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2011 Foreman 500S

High Lifter Signature Lift
High Lifter 1" Wheel Spacers
High Lifter Pull Starter Leak Shield
Turners Cycle HD U Joint
Turners Cycle Gear Reduction
Warn XT25 Winch
Dynojet Jet Kit
2" Dual Snorkels w/ Rerouted Vent Lines
K&N Air Filter
HMF Utility Pipe
EPI Clutch Kit
High Lifter 29.5" Outlaw 2 Tires S/W
ITP 14" SS212 Black Wheels

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motor work and irs

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Old 10-05-2012, 10:58 AM   #8 (permalink)
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try covering some of the hole on the air box with apiece of tape and see if it dies when you take it off choke
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Old 10-06-2012, 02:21 PM   #9 (permalink)
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My bike had same problem there was a vacuum port top towards the engine that hooks to the air stop valve, but the kid i got it from had it vented and was pulling in air. No problems since.
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Old 10-07-2012, 01:56 PM   #10 (permalink)
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I got it running but still some carb issues. It still sounds like its starving for fuel every once in a while, and the float is getting stuck. I'll shut it off and tons of gas come pouring out of the overflow. I did get a chance to ride it down the driveway, runs and shifts pretty smooth for the most part. Clutch still needs adjusted and there is a little front end noise i still have to mess with.
__________________
2011 Foreman 500S

High Lifter Signature Lift
High Lifter 1" Wheel Spacers
High Lifter Pull Starter Leak Shield
Turners Cycle HD U Joint
Turners Cycle Gear Reduction
Warn XT25 Winch
Dynojet Jet Kit
2" Dual Snorkels w/ Rerouted Vent Lines
K&N Air Filter
HMF Utility Pipe
EPI Clutch Kit
High Lifter 29.5" Outlaw 2 Tires S/W
ITP 14" SS212 Black Wheels

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