Extended Swing Arm - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum

Duke70 · 08-04-2009, 11:41 PM

Disclaimer: Hondaforeman.com & Duke70 is not responsible for any damage caused to you or your bike.

I built a lift to work with it instead of cuttin the top of the shocks

I'm also in the prosses of extending the 500 arm so it will be a
direct bolt on and I will have to change very little on the lift for it
that I designed for the 450 arm on a 500

Swing-arm Conversion 450 arm on a 500
Foreman & Rubicon

98 to 04 450 arm and drive shaft, the 450 arm
is 2 1/2" longer then the 500 arm the u-joints
are the same so you can use your stock u-joint
the 450 arm is about 1/4" wider where it bolts
on between the differential an the brake drum

Pivot Bolts: left side is a 17mm allen bolt
right side is a lock nut on a 17mm allen bolt
this requires a special tool to remove
some use a steel punch to remove the lock nut
which can mess-up the lock nut and if you hit
wrong can also mess-up the treads, be very
careful doing this, I made a tool to do this

Pivot bearings: there are to different part #'s
on these bearings this does not make a difference
1 set of bearings are ball & the other set are needle
bearings they will both work

Swing-arm: where the arm bolts up to the differential
the O-ring on the 450 arm is smaller then the 500
when you take the 500 arm off the O-ring should stay
on the differential leave it on there and the 450 arm
the O-ring should still be on it as well use them both
this will make for a tighter seal

450 to 500 rear-end mounting: loosen the right side
alxe tube from the differential, do not take these nuts
all the way off, where the arm bolts to the tube by the
brake drum, you will take a hammer and slightly bend
the tab to the right, this will give it an angle/taper
this will help on mounting the 450 arm on the 500 rear-end
it's still a tight fit, once you get it together place the
bolts in the bent tab and snug them up as well as the nuts
on the differential

Shocks/Lift: some cut the top of the shock off and take a
piece of pipe and weld it to the shock to extend it to makeup
for the the difference in the arm's but this puts your shocks
at a bad angle and will make it ride like a tank
I designed my on lift to move the bottom of the shocks forward
which makes for a nice ride

Torque Specs: Pivot Bolts
left side 83 ft lbs
right side 3 to 7 ft lbs
right side lock nut 83 ft lbs

localfiremedic · 08-04-2009, 11:51 PM

Thanks for the info. I read earlier that it looks like there's a frame difference and swingarm difference from 06 to 07. Is this confirmed? Doesn't seem like honda would change this on the same model

Duke70 · 08-05-2009, 12:08 AM

QUOTE (localfiremedic @ Aug 5 2009, 03:51 AM)

Quote:

Thanks for the info. I read earlier that it looks like there's a frame difference and swingarm difference from 06 to 07. Is this confirmed? Doesn't seem like honda would change this on the same model

Not that I know of on the frame,

Honda went back to the old style roller bearings in 07 likes in the 01 arm I put on my 06,

My 06 had tappered bearings in the 500 arm

I think the old style roller bearings are alot stronger then the tappered bearings

I am biulding a lift for a guy in TN now that is puttin the 450 arm on his 08

localfiremedic · 08-05-2009, 10:56 AM

QUOTE (Duke70 @ Aug 5 2009, 12:08 AM)

Quote:

Not that I know of on the frame,

Honda went back to the old style roller bearings in 07 likes in the 01 arm I put on my 06,

My 06 had tappered bearings in the 500 arm

I think the old style roller bearings are alot stronger then the tappered bearings

I am biulding a lift for a guy in TN now that is puttin the 450 arm on his 08

Well keep us posted as this winter I plan on breaking down my 07 and doing this along with a GR. Might be interested in one of those lifts you're making as well

cuz I'm gonna wanna keep my 2in's of lift I have right now when I do it

onebad420a · 08-05-2009, 09:12 PM

I thought about loosening the axle tube and trying that but was scared the pressure from pulling it all togeather would break the alum. diff houseing or pull the studs out of it

Duke70 · 08-05-2009, 09:47 PM

QUOTE (onebad420a @ Aug 6 2009, 02:12 AM)

Quote:

I thought about loosening the axle tube and trying that but was scared the pressure from pulling it all togeather would break the alum. diff houseing or pull the studs out of it

It is a tight fit

There really isn't any presure there, The biggest thing is to tighten the bolts slow and in a cross pattern the arm will start to bend in with no problem

What I did was bend the front mount on the tube but not to much that the bolts wouldn't go back in and also I bent the ends the other way just alittle on the arm

When any of you decide to do this and doesn't understand it completely just send me a PM and I will help you all I can

This setup works great and makes for a nicer ride

jrfonte1479 · 08-08-2009, 03:04 PM

[quote]
Disclaimer: Hondaforeman.com & Duke70 is not responsible for any damage caused to you or your bike.

Swing-arm: where the arm bolts up to the differential
the O-ring on the 450 arm is smaller then the 500
when you take the 500 arm off the O-ring should stay
on the differential leave it on there and the 450 arm
the O-ring should still be on it as well use them both
this will make for a tighter seal

why not just get an 02 + 450 swing arm then you dont have to worry about the o ring there both the same size 75 x 3.2mm .

Duke70 · 08-08-2009, 03:52 PM

Disclaimer: Hondaforeman.com & Duke70 is not responsible for any damage caused to you or your bike.

I using this as an Example:

( You find a 01, 450 arm for $100. )
&
( You find a 02, 450 arm for $150. )

( Which 1 are you gonna buy? )

So the 01 arm has a smaller O-ring you really don't have to
use it but it gives you a double seal, I gonna use them both

Now if I would had come across a 02 arm my write up here would had still been the same

budmc77 · 08-09-2009, 01:23 AM

QUOTE (Duke70 @ Aug 4 2009, 11:41 PM)

Quote:

Disclaimer: Hondaforeman.com & Duke70 is not responsible for any damage caused to you or your bike.

I built a lift to work with it instead of cuttin the top of the shocks

I'm also in the prosses of extending the 500 arm so it will be a
direct bolt on and I will have to change very little on the lift for it
that I designed for the 450 arm on a 500

Swing-arm Conversion 450 arm on a 500

98 to 04 450 arm and drive shaft, the 450 arm
is 2 1/2" longer then the 500 arm the u-joints
are the same so you can use your stock u-joint
the 450 arm is about 1/4" wider where it bolts
on between the differential an the brake drum

Pivot Bolts: left side is a 17mm allen bolt
right side is a lock nut on a 17mm allen bolt
this requires a special tool to remove
some use a steel punch to remove the lock nut
which can mess-up the lock nut and if you hit
wrong can also mess-up the treads, be very
careful doing this, I made a tool to do this

Pivot bearings: there are to different part #'s
on these bearings this does not make a difference
1 set of bearings are ball & the other set are needle
bearings they will both work

Swing-arm: where the arm bolts up to the differential
the O-ring on the 450 arm is smaller then the 500
when you take the 500 arm off the O-ring should stay
on the differential leave it on there and the 450 arm
the O-ring should still be on it as well use them both
this will make for a tighter seal

450 to 500 rear-end mounting: loosen the right side
alxe tube from the differential, do not take these nuts
all the way off, where the arm bolts to the tube by the
brake drum, you will take a hammer and slightly bend
the tab to the right, this will give it an angle/taper
this will help on mounting the 450 arm on the 500 rear-end
it's still a tight fit, once you get it together place the
bolts in the bent tab and snug them up as well as the nuts
on the differential

Shocks/Lift: some cut the top of the shock off and take a
piece of pipe and weld it to the shock to extend it to makeup
for the the difference in the arm's but this puts your shocks
at a bad angle and will make it ride like a tank
I designed my on lift to move the bottom of the shocks forward
which makes for a nice ride

Torque Specs: Pivot Bolts
left side 83 ft lbs
right side 3 to 7 ft lbs
right side lock nut 83 ft lbs

That second pic of your lift, looks juss like my Perplex setup..You done a good job on it.

budmc77 · 08-09-2009, 01:31 AM

Here is a pic of mine, sorry but not a good pic but its the only one i had right now

08-04-2009, 11:41 PM	#1 (permalink)
Duke70 Super Moderator Join Date: May 2009 Location: New Bern, NC Posts: 454	Disclaimer: Hondaforeman.com & Duke70 is not responsible for any damage caused to you or your bike. I built a lift to work with it instead of cuttin the top of the shocks I'm also in the prosses of extending the 500 arm so it will be a direct bolt on and I will have to change very little on the lift for it that I designed for the 450 arm on a 500 Swing-arm Conversion 450 arm on a 500 Foreman & Rubicon 98 to 04 450 arm and drive shaft, the 450 arm is 2 1/2" longer then the 500 arm the u-joints are the same so you can use your stock u-joint the 450 arm is about 1/4" wider where it bolts on between the differential an the brake drum Pivot Bolts: left side is a 17mm allen bolt right side is a lock nut on a 17mm allen bolt this requires a special tool to remove some use a steel punch to remove the lock nut which can mess-up the lock nut and if you hit wrong can also mess-up the treads, be very careful doing this, I made a tool to do this Pivot bearings: there are to different part #'s on these bearings this does not make a difference 1 set of bearings are ball & the other set are needle bearings they will both work Swing-arm: where the arm bolts up to the differential the O-ring on the 450 arm is smaller then the 500 when you take the 500 arm off the O-ring should stay on the differential leave it on there and the 450 arm the O-ring should still be on it as well use them both this will make for a tighter seal 450 to 500 rear-end mounting: loosen the right side alxe tube from the differential, do not take these nuts all the way off, where the arm bolts to the tube by the brake drum, you will take a hammer and slightly bend the tab to the right, this will give it an angle/taper this will help on mounting the 450 arm on the 500 rear-end it's still a tight fit, once you get it together place the bolts in the bent tab and snug them up as well as the nuts on the differential Shocks/Lift: some cut the top of the shock off and take a piece of pipe and weld it to the shock to extend it to makeup for the the difference in the arm's but this puts your shocks at a bad angle and will make it ride like a tank I designed my on lift to move the bottom of the shocks forward which makes for a nice ride Torque Specs: Pivot Bolts left side 83 ft lbs right side 3 to 7 ft lbs right side lock nut 83 ft lbs Attached Thumbnails __________________ To all members PLEASE add your location to your profile 06 Honda Foreman 500s 30'' Mudlites HL Springs & 2'' SS lift front 01 450 swingarm custom lift rear Custom Built Snorkel & Powder Coated 2500 Warn Winch Warn Front Bumper Benson Rear Bumper 170 main-jet & 48 slow-jet K&N air & oil filters Powder Coating http://www.pcitdad.com/ Rear Lift for Swing-arm Conversion 450 arm on a 500 http://www.pcitdad.com/lift-kit.html Last edited by Duke70; 01-21-2012 at 12:57 PM. Reason: Updated INFO & Pictures

08-04-2009, 11:51 PM	#2 (permalink)
localfiremedic Honda Lover Join Date: Apr 2009 Location: Albany, Ga Posts: 419	Thanks for the info. I read earlier that it looks like there's a frame difference and swingarm difference from 06 to 07. Is this confirmed? Doesn't seem like honda would change this on the same model __________________ 07 Foreman 500 4x4 with some goodies (SOLD) ...and moved on to an Arctic Cat Rolling with The Pride... http://www.youtube.com/user/carpeonnel?feature=mhum

08-05-2009, 09:12 PM	#5 (permalink)
onebad420a Honda Lover Join Date: Aug 2008 Location: Effingham IL Posts: 301	I thought about loosening the axle tube and trying that but was scared the pressure from pulling it all togeather would break the alum. diff houseing or pull the studs out of it __________________ 08 Foreman S white the albino honda mods -fmf jet kit -warn xt25 winch -k&n filter with precharger -black ITP ss212s -29.5x10x12 outlaws front -29.5x12x12 outlaws rear -DIY dual snorkle kit -NGK I Plug -2inch SS atv lift -pucked rear -450 swingarm and custom rear lift -05 esclade HID for center headlight Drive it like you stole it

08-08-2009, 03:04 PM	#7 (permalink)
jrfonte1479 Honda Red Wing Rider Join Date: Feb 2009 Location: se texas Posts: 804	[quote] Disclaimer: Hondaforeman.com & Duke70 is not responsible for any damage caused to you or your bike. Swing-arm: where the arm bolts up to the differential the O-ring on the 450 arm is smaller then the 500 when you take the 500 arm off the O-ring should stay on the differential leave it on there and the 450 arm the O-ring should still be on it as well use them both this will make for a tighter seal why not just get an 02 + 450 swing arm then you dont have to worry about the o ring there both the same size 75 x 3.2mm . __________________ 08 black 700 rhino (sold) 03 yellow 450s (sold) 07 black 500 (sold) i no longer own any hondas but they wont be forgotten especially the black 1 10 750 blue nocturnal brute

08-08-2009, 03:52 PM	#8 (permalink)
Duke70 Super Moderator Join Date: May 2009 Location: New Bern, NC Posts: 454	Disclaimer: Hondaforeman.com & Duke70 is not responsible for any damage caused to you or your bike. I using this as an Example: ( You find a 01, 450 arm for $100. ) & ( You find a 02, 450 arm for $150. ) ( Which 1 are you gonna buy? ) So the 01 arm has a smaller O-ring you really don't have to use it but it gives you a double seal, I gonna use them both Now if I would had come across a 02 arm my write up here would had still been the same __________________ To all members PLEASE add your location to your profile 06 Honda Foreman 500s 30'' Mudlites HL Springs & 2'' SS lift front 01 450 swingarm custom lift rear Custom Built Snorkel & Powder Coated 2500 Warn Winch Warn Front Bumper Benson Rear Bumper 170 main-jet & 48 slow-jet K&N air & oil filters Powder Coating http://www.pcitdad.com/ Rear Lift for Swing-arm Conversion 450 arm on a 500 http://www.pcitdad.com/lift-kit.html

08-09-2009, 01:31 AM	#10 (permalink)
budmc77 Honda Rider Join Date: Feb 2009 Location: Martin County, Kentucky Posts: 78	Here is a pic of mine, sorry but not a good pic but its the only one i had right now Attached Thumbnails __________________ '02 Honda Rubicon 500 -Warn 2000lb Winch -Warn 424 Select -Warn Pushbar -Perplex 2" Lift -25" ITP MudLite Tires -Highlifter Front Disc Brake Converstion Kit -Hand Warmers If it's worth doing the first time, it's worth doing right

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