Need Top End Rebuild Info - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum
 
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post #1 of 7 (permalink) Old 06-04-2008, 10:29 PM Thread Starter
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Join Date: Sep 2007
Location: Memphis,Tn.
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Need Top End Rebuild Info

After drowning my Foreman a few times it started smoking so I pulled the head and cylinder to have a look. I believe I need to bore the cylinder up a size and replace the piston, gaskets and rings. I cannot seem to find a place online that sells oversize pistons and rings for this bike. Can anyone direct me to a good place so I can get the parts ordered? Also, I checked the rod for slack in the bearing and I didnt feel any pushing up and down on it against the crankshaft but it did have some side to side play. Does anyone know what is an acceptable amount before I reassemble the top end? This is my first top end rebuild on this bike so any comments or suggestions will be highly appreciated. Thanks

05 Foreman S
28" Highlifter Outlaws
ITP C-Series Wheels
2" Highlifter Lift Kit
HMF Penland Exhaust
.170 Main Jet
Strobe Lights
Mini Bud Light Truck on Back
Audiopipe
Custom Snorkel
Southernmudslingers.com
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post #2 of 7 (permalink) Old 06-04-2008, 11:17 PM
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side to side is normal, up and down is what you need to worry about and this you do not want. you need to have the cylinder checked before you order anything, it could be scared or even out of round and may need to go 2 sizes up. the shop that does the overbore for you should be able to order the pistion kit of your choice which they will need before boring.

Now the bad news, you said the bike has been sunk numerous times, a new top end may not last long. If you want it to last the bottom end needs to be split open and everything cleaned out good along with the oil cooler. I hate to see you spend $300 in just parts then for it to crap out on you in a month or two, if your lucky you may get a year out of it but who knows.

98/01 Foreman 400/450 Halfbreed with to much to list according to the site
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post #3 of 7 (permalink) Old 06-09-2008, 10:51 PM Thread Starter
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Thanks for the info here... I should have parts in this week but now I have a new request for dirty4man or anyone else. Anyone know the torque specs for the jug and cylinder head? Thanks

05 Foreman S
28" Highlifter Outlaws
ITP C-Series Wheels
2" Highlifter Lift Kit
HMF Penland Exhaust
.170 Main Jet
Strobe Lights
Mini Bud Light Truck on Back
Audiopipe
Custom Snorkel
Southernmudslingers.com
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post #4 of 7 (permalink) Old 06-10-2008, 04:13 AM
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Join Date: Nov 2006
Location: Memphis, tn
Posts: 414
thought you were going with the BBK??? what happened to that idea??? or was that the budweiser talking lol??? whenever i have to rebuild mine i think im going to go .60 over lil bit more power without haveing to worry about overheating... im ready to ride with ya'll again whenever u ride hatchies, i'll ride with u and i'll park wherever u park... i had fun with u and everyone else last time... this next time i wont be so wore out... last time i didnt go to sleep the night before... let me know when u get it back running, DONT SELL YOUR FOREMAN either
heres a few pics from coon creek

2006 Yellow Honda foreman 500s
27-12.5-12 mudlite rears 27-10-12 fronts
Itp type 7 polished wheels
HMF pipe
Dyno jet kit
Uni filter
2500 warn winch
Yellow Truck Nutz
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post #5 of 7 (permalink) Old 06-10-2008, 04:27 AM
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well, nevermind i dont know why sometimes i can post pictures and sometimes this **** wont let me do nothing

2006 Yellow Honda foreman 500s
27-12.5-12 mudlite rears 27-10-12 fronts
Itp type 7 polished wheels
HMF pipe
Dyno jet kit
Uni filter
2500 warn winch
Yellow Truck Nutz
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post #6 of 7 (permalink) Old 07-02-2008, 05:43 PM
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im not sure of the the torque needed but u can get wiseco high compression piston and rings on ebay for $80 thats were i got mine

04 Yellow Foreman 450
475cc big bore
Wiseco High Compression piston
Port and Polished heads
HMF Exhaust
Dyno Jet
Bi/Tri Claw Tires
ITP Black LTD Type 7 Rims
Pro Grips
2" Snorkel
HL Pull-Start Leak Shield
HL 2in Lift Kit
HL Bash Plate
HL Axle Guards
Rerouted Vent Lines
Reverse Mod
Stock Decals Removed
MUD MAFIA



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post #7 of 7 (permalink) Old 07-03-2008, 01:13 PM
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the cylinder head cap nuts are 29 ft-lb, tighten in several steps in a criss-cross pattern. the 6mm bolts on the cylinder, head, and cover should be tourqued to 9 ft-lb.



2007 420FM (475cc, 27x12x12 Mudbugs) ---------- 1995 300FW (webcamshaft, 350 rear end)
2008 420FE (26x9x12 BearClaws) -------------------
1988 300 (old stock machine, nothing fancy)
2009 420FA (25x8/10x12 BearClaw HTR) ---------
1987 350D (work in progress)

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