Toddub

I just picked up a 1999 Foreman 450ES from an ad on Craigslist for $400.

The family I purchased it from were riding it this past weekend when the motor locked up. They seemed to think that the crank bearing had seized up. At any rate they didn't want to put any more money into it and just wanted to get rid of it so they could go buy a new one. By the looks of their house, trucks and other 4 wheelers, they could afford it.

The engine was indeed locked up. I was able to remove the recoil starter and turn the engine over backwards by hand. After pulling the valve cover and sparkplug I could tell the piston was going up and down, but the rocker arms were not moving at all.

I pulled the clutch cover and found that the cam chain had snapped, also destroying the tensioner. The clutch components look to be undamaged. The problem is that I stood the Foreman up on its back end to make accessing the clutch cover easier. I am afraid that small pieces of the plastic tensioner may have slid down a 1/2" hole that leads into the crankcase.

I have 2 questions

Has anyone used a D.I.D. cam chain? they are about 2/3 less expensive than the Honda part.

What, if anything, can I use to flush out the crankcase, or am I going to have to pull the motor and split the cases?

Any input would be appreciated.

foreman480

i have always used honda dont skimp on your engine, but look on ebay you can probably get it cheaper.
and no you dont have to pull the engine and split the case for the timing chain

__________________
'95 foreman 480---SOLD!
looking for the next one might have to go to the dark side (non honda)

toodeep

I have yet to see an OEM chain break, there could be more problems or the tensioner was bad to start with and they rode it too long. A long time ago I have used a few of the cheaper cam chains in the old 3 wheelers and they don't last as long as the OEM, not sure about nowadays since I stick with only OEM parts on stuff like that.

If it's just a couple of little plastic pieces I wouldn't worry about them. The internal oil screen will filter them out and not cause any damage.

Toddub

Yeah, I kinda figured that when I was able to remove the old cam chain without having to split the cases. I am more concerned about debris in the crankcase.

Toddub

Okay, I ordered all factory Honda Parts this afternoon from hondaparts-direct.com in Marshall, TX.

I got a new cam chain and tensioner, guide, gasket set A, clutch cover gasket a couple of oil filters, 2 new rear mudgaurds and 20 plastic push screws for $301.

I will have just over $700 in this when completed. That will leave me with some room to see if I can find an Odyessy Battery while I am waiting for the parts to come in.

foreman480

yep if you can find a non running fourwheeler you can usually fix it for little price and have a good fourwheeler and still be able to sell it for much more than its worth.
and as far as the plastic pieces i agree with toodeep dont worry about it

__________________
'95 foreman 480---SOLD!
looking for the next one might have to go to the dark side (non honda)

toodeep

With the front cover off you could set the machine back down and jack up the rear of the bike. The pieces might find there way back to the front and out.

What's your plan for changing the adjuster? Are you going to pull the top end off or remove the bottom fin above the adjuster and change it? If you pull the top end off you can get in there and spray some cleaner to help get the pieces moving.

Toddub

I pulled the top end off while trouble shooting.

I purchased this 4 wheeler not knowing what was wrong.

The new parts came in today and I am in the process of putting it back together. Alot of the time was devoted to scrapping off old gasket material. I am fairly confident there is nothing major in the crankcase.

toodeep

Those gaskets can be a pain. I use a spray on paint/gasket remover, after they soak in it awhile they about fall off.