MET1288

Hello all,

I'm a newbie that's been snooping around and reading up. I have a 1999 450ES that belonged to my Grandfather and has bounced around the family it's whole life. I'm certain it has been neglected at times. Last time it was out of the barn, my fiancees brother was running it harder than usual and it developed a "chatter" and rub like "whine" from the clutch area. Of course the clutch adjustment was frozen so I sucked it up and opened it up. Here's a few interesting findings:

First I located a "mystery" washer laying in the centrifugal clutch, not quite sure where it came from during the teardown:


Next I noticed abrasion marks on the clutch weights and honestly I'm not sure how they would have been made:


The next finding was dirty, stuck clutch disks:




And last but certainly not least I found the source of the chatter. Luckily the gear fragment was in the bottom of the case:


I'm planning on replacing the clutch disks and plates, clutch outer, and primary drive gear (teeth have slight edging). This is my first go round with an ATV clutch system. Is there anything else I should be replacing or specifically looking at while I'm in this deep? What are other tell tail signs of trouble?

Also, who makes the best replacement clutch parts for the best price?

The machine is now mine, and it's getting a thorough going over. Hopefully the lack of maintenance hasn't yet killed it! It has roughly 727 hours and about 4084 miles logged.

I know it was a novel, but hopefully your wisdom will help my lack-there-of! Thanks for any input and thanks for an awesome site!

Mark

lop3r1

i haven't dug into mine that far...yet! so, i won't be able to help you...but, someone very knowledgeable will reply shortly.

__________________
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

rich450es

welcome to the forum !
ill sell you the clutchbasket with good clutchdisks (in mint condition )for $20 pluss shipping
pm me if you want it

__________________
2000 foreman 450 es-s
the f**king 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

rich450es

the washer is #16 in the link below
Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

__________________
2000 foreman 450 es-s
the f**king 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

Wingman

You definately have something wrong with the Centrifigal clutch with them clutch dogs being all scraped up like that and I would imagine thats where your chatter is coming from.
Its been awhile since redoing both my clutches so Id have to go back and look at some pics to figure out whats wrong there but you definately have something wrong.

__________________
Honda 1998 Foreman 450s (Starburst Yellow)
SS ATV 2in lift
Maxxis Bighorn 2.0 tires
Aluminum Products Bash plate
Viper 3500 winch & Cycle country 52in plow
ES floorboard conversion

HONDA!!! No Wing! No Prayer!!

MET1288

Rich,

Thanks for your help! I'll gladly take the clutchbasket, PM you shortly.

How concerned should I be with the centrifugal clutch weights? The linings look to be within spec, but seem quite built up with grime. Clean'em up or replace? also, any idea what the abrasion marks on them might be from?

brutus750i

theres your man to talk to,also if your gonna add big tires anytime soon nows the time for a gear reduction,best mod that ive done!

__________________
29.5 wide laws on all 4 corners on 12 inch ss wheels,full snorks front an rear,homemade winch bumper with 2500 winch,2 in lift with hl springs,14% gear reduction,rear led brake light,disc brakes,tool tubes,a arm skids,2.5 inch rear spacers,cut floorboards with frame riser mod all this on an 04 foreman. kids 01 foreman on 27 mud machine tri claws wide on all 4 corners,snorked.

MET1288

Wingman,

I'm scratching my head because I can't see how anything would strike them that far out towards the end. Anyone have any ideas?

rich450es

see if the pins that the centrifical clutch weights slide threw are worn some ....i have a centrifical clutch out of a fourtrax 300 ill give you also (i dont know if the parts are the same) but the weights may.....

__________________
2000 foreman 450 es-s
the f**king 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

MET1288

I'll check the pins better as I didn't disassemble the clutch insides entirely. Everything seemed firm at first glance, but with those marks, something had to happen!