2001 Foreman 450S cam chain - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum
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Old 03-13-2013, 01:02 PM   #1 (permalink)
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Default 2001 Foreman 450S cam chain

Going to be doing a cam chain on a 2001 Foreman 450S for a buddy of mine. He talked me into doing the work for pizza and beer. I might of gotten the short end of the stick. We went for a few long rides together and he told me hey this thing has been making a weird tapping noise since we went riding 3 weeks ago and it hasn't stopped. Upon some searches and such found the noise is the cam chain. He just had the top end rebuilt last summer.


I went ahead and ordered the chain, tensioner, the plastic guide, the tensioner on the outside, and some gaskets. Got all the parts for 225.00 shipped to his house.

Questions.

Removing the clutch. Do I need anything special to do this? The service manual lists a holder tool, can i get creative and hold it with some bolts or a strap wrench? As for pulling it will a 3 jaw puller work?

Major question, would it be worth it just to pull the entire engine and sit it on the work bench or try to just remove the plastics and tires and try to squeeze my melon head and fat hands back in there?

Haven't really worked on a quad in a long time. Had a RZR since 08 and spent my time working on them. Polaris makes things super difficult to work on, hoping maybe the Honda will be a lot easier. I remember them being that way anyway.
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Old 03-13-2013, 01:16 PM   #2 (permalink)
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ok first thing is Welcome to the forum !!!
next to get the nuts off just hit them with a impact gun wile holding the clutch with youre hand (ware a heavy leather glove , i use a welding glove ) because it will want to spin
next to get the cyntrifical clutch off i just bang behind it with a plastic dead blow hammer
here is the PITA about doing this job ........to replace the tensioner you will need to remove the top end .....unless you want to break a shitload of cooling fins off the jug .........
i stand it on its rear rack to do this work but its up to you if you take it out
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Old 03-13-2013, 04:42 PM   #3 (permalink)
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Thanks for the welcome!

I've been a long time Honda owner. 87 TRX250, 1990 250X, 1997 300EX, 2000 300EX(later a 352 built by Four stroke tech), a 2005 400EX, a 2012 400X(bought off a friend going through a divorce, sold a few months later back to him), and still have a 2012 250 Recon ES that the wife drives when our daughter wants to go in the RZR since she is too small to ride the trails on her 50!

I think we will attempt to do it by pulling the tires, draining oil and fuel then standing it up on end.

Could I take a dremel and trim cooling fins?

I really don't want to pull the top end if i don't have to.

Any chance the tensioner itself is still good? I plan on changing the lower piece for sure along with the plastic wear strip on the bottom of the case.
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