2004 Rincon questions - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum

Wingman · 04-30-2011, 11:15 AM

I just picked up this Rincon 2 days ago and it starts and runs really well but it has this funky noise that sounds like a metal pingpong ball bouncing around in the exhaust.
It makes this noise when you first fire it up and then is almost non existant when its warm but comes and goes.
When it makes this noise it doesnt affect the engine idle what so ever as this bike runs perfect and has no tick, Taps, or smoke, Just the ping pong ball in the exhaust sound.
The person I bought the bike from said thats it been doing this for the last year and has never gotten worse or affected the way it runs.
Its missing its exhaust baffle and all three bolts are snapped off in it and I think the guy thought the same thing and that it has a rock or something in there.lol

Other than cosmetics I only have 2 other huge issues with this bike and 1 being my display is not working and has a hole on the clear lens and the other problem I have is it wont go into reverse and just grinds when you try to move the lever into position.
I have yet to tear into this and plan to do some reading on this site but has anyone ever had this Ping pong ball in the exhaust type sound and what was it?
Oh and if does anyone have manual for this bike I can download? Thanks

MattT · 04-30-2011, 01:05 PM

There's an '03 manual here.

Wingman · 05-09-2011, 01:12 AM

BUMP! lol
Thanks Matt! But my puter is John F Kennedy ERA! lol
But Ive narrowed the sound down to the front of motor and its in the timing chain area.
Does anyone have any idea what it could be?
I mean the sound comes on hard when cold but after its warm it only happens every couple of minutes and then its only a very quiet click noise here and there?
The bike runs absolutely perfect!! Any ideas anyone?

RidinDirty 03 · 05-09-2011, 03:34 AM

Mines doing the same as you described. I had some one look at it and they believed it is the timing chain has slop in it and it's slapping the case. My tensioner is maxed out so the chain is lose. I have it at the Honda mechanic waiting for them to get a chance to look at it to confirm but it will be a few more days before they even get a chance to look at it. I'll let you know what I find out.

Wingman · 05-10-2011, 05:23 PM

Well I just got done playing around with my cam chain tensioner and im thinking it might be where my noise is coming from.
I didnt remove the tensioner yet because I dont have a manual and I cant remember if you have to have the engine TDC in order to reinstall it?
But I stuck a screw driver in it and could turn it clockwise really easy and I mean really!!! easy and Im thinking it should be alot stiffer than that in order to keep a timing chain tight? I release it and it does turn back on its own but it doesnt seem like it has much recoil?A few years ago I rebuilt the top end on a 400ex and if I remember correctly? It had a whole lot more spring to it.
I could only turn it counter clockwise about a quarter turn so Im assuming thats because its putting pressure on the cam chain? Kinda stumped?
So then I figured Id fire up the bike and turn the screw on the tensioner to see if it makes the noise go away in either direction.
As soon as I stuck the screw driver in the hole I could Immediately feel rapping vibration consistent with the noise in the engine and could barely get the screwdriver to fit in the slot.
I turned it clockwise and it (the sound) got really loud and when I turned it counter clockwise it (the sound and rapping) went away and stayed away even after I removed the screw driver? Of course this is not the fix because as soon as I let it cool down Im pretty sure it (the sound) will be back! lol
One thing I know now for sure is that rapping noise is definately the chain rapping the back side of the Chain tensioner but Im not absolutely sure whether its a tensioner or stretched chain?
Can anybody give me pointers on the process of removing and replacing the cam chain tensioner? I know how it operates but I just cant remember if you have to have the engine at TDC in order to reinstall it? Thanks

Wingman · 05-10-2011, 06:47 PM

Ok, I just let it cool down for an hour and a half and went to start it and the noise is gone!
I cant believe it, I mean this thing always makes the sound at start up and only goes away when bike is hot and even when hot it will make a click here and there but i just let it run awhile and zip notta.
I am gonna wait till tommorow morning to try it again and if there is no sound im pretty sure I fixed it for now.
Keeping my fingers crossed! lol

Wingman · 05-11-2011, 11:06 PM

Ok, I started it today about noon, so it was bone cold, and the initial start up noise is definately gone but I did notice a lil click every now and again after it was warm so we will see after I take it for a ride?
Dont get me wrong!, My gauge pod does not work and I have no idea how many hours or miles are on my machine but im pretty sure it needs both the oil and cam chain replaced along with tensioner and guides. But right now funds are limited(I just used half a roll of black duct tape on the seat! lol) and im just trying to hump by until the economy picks back up and I can afford to really throw down on this thing.lol
Oh and FYI, I was snoopin around on the Reconrider site and came across a posting about how to tell how worn out your chain and guides are.
According to the poster you simply count out how many turns it takes on the adjuster clockwise until it stops.
A brand new one stops in 2.5 turns and a really worn out one stops at 4 turns.
Mine stops at just little over 3.25 turns so im thinking mine is **** near wore out!
For now, Im just hoping for the best!

RidinDirty 03 · 05-12-2011, 08:26 PM

Talked to the mechanic today and that's what's wrong with mine. It needs a new tensioner. It's like 70 bucks installed. Should be done tomorrow.

Wingman · 05-13-2011, 09:21 PM

Ridindirty, Let me know how that works out for you cause its only 47 bux for the part and if it fixes your problem I may just go and buy one myself.

RidinDirty 03 · 05-20-2011, 07:44 AM

Quote:

Originally Posted by Wingman

Ridindirty, Let me know how that works out for you cause its only 47 bux for the part and if it fixes your problem I may just go and buy one myself.

Got it back from the shop and haven't had much time to ride it but the noise is no longer there.

04-30-2011, 11:15 AM	#1 (permalink)
Wingman Honda Red Wing Rider Join Date: Mar 2010 Location: Rockford Illinois Posts: 933	2004 Rincon questions I just picked up this Rincon 2 days ago and it starts and runs really well but it has this funky noise that sounds like a metal pingpong ball bouncing around in the exhaust. It makes this noise when you first fire it up and then is almost non existant when its warm but comes and goes. When it makes this noise it doesnt affect the engine idle what so ever as this bike runs perfect and has no tick, Taps, or smoke, Just the ping pong ball in the exhaust sound. The person I bought the bike from said thats it been doing this for the last year and has never gotten worse or affected the way it runs. Its missing its exhaust baffle and all three bolts are snapped off in it and I think the guy thought the same thing and that it has a rock or something in there.lol Other than cosmetics I only have 2 other huge issues with this bike and 1 being my display is not working and has a hole on the clear lens and the other problem I have is it wont go into reverse and just grinds when you try to move the lever into position. I have yet to tear into this and plan to do some reading on this site but has anyone ever had this Ping pong ball in the exhaust type sound and what was it? Oh and if does anyone have manual for this bike I can download? Thanks __________________ 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!!

05-09-2011, 01:12 AM	#3 (permalink)
Wingman Honda Red Wing Rider Join Date: Mar 2010 Location: Rockford Illinois Posts: 933	BUMP! lol Thanks Matt! But my puter is John F Kennedy ERA! lol But Ive narrowed the sound down to the front of motor and its in the timing chain area. Does anyone have any idea what it could be? I mean the sound comes on hard when cold but after its warm it only happens every couple of minutes and then its only a very quiet click noise here and there? The bike runs absolutely perfect!! Any ideas anyone? __________________ 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!!

05-09-2011, 03:34 AM	#4 (permalink)
RidinDirty 03 Honda Rider Join Date: Mar 2010 Location: ramsey, il Posts: 57	Mines doing the same as you described. I had some one look at it and they believed it is the timing chain has slop in it and it's slapping the case. My tensioner is maxed out so the chain is lose. I have it at the Honda mechanic waiting for them to get a chance to look at it to confirm but it will be a few more days before they even get a chance to look at it. I'll let you know what I find out. __________________ BOILERMAKER L.U. 363 03 rincon 650 27" itp mudlites on 14" itp rims 03 foreman 450s 26" super swamper vampires winch that don't work

05-10-2011, 05:23 PM	#5 (permalink)
Wingman Honda Red Wing Rider Join Date: Mar 2010 Location: Rockford Illinois Posts: 933	Well I just got done playing around with my cam chain tensioner and im thinking it might be where my noise is coming from. I didnt remove the tensioner yet because I dont have a manual and I cant remember if you have to have the engine TDC in order to reinstall it? But I stuck a screw driver in it and could turn it clockwise really easy and I mean really!!! easy and Im thinking it should be alot stiffer than that in order to keep a timing chain tight? I release it and it does turn back on its own but it doesnt seem like it has much recoil?A few years ago I rebuilt the top end on a 400ex and if I remember correctly? It had a whole lot more spring to it. I could only turn it counter clockwise about a quarter turn so Im assuming thats because its putting pressure on the cam chain? Kinda stumped? So then I figured Id fire up the bike and turn the screw on the tensioner to see if it makes the noise go away in either direction. As soon as I stuck the screw driver in the hole I could Immediately feel rapping vibration consistent with the noise in the engine and could barely get the screwdriver to fit in the slot. I turned it clockwise and it (the sound) got really loud and when I turned it counter clockwise it (the sound and rapping) went away and stayed away even after I removed the screw driver? Of course this is not the fix because as soon as I let it cool down Im pretty sure it (the sound) will be back! lol One thing I know now for sure is that rapping noise is definately the chain rapping the back side of the Chain tensioner but Im not absolutely sure whether its a tensioner or stretched chain? Can anybody give me pointers on the process of removing and replacing the cam chain tensioner? I know how it operates but I just cant remember if you have to have the engine at TDC in order to reinstall it? Thanks __________________ 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!!

05-10-2011, 06:47 PM	#6 (permalink)
Wingman Honda Red Wing Rider Join Date: Mar 2010 Location: Rockford Illinois Posts: 933	Ok, I just let it cool down for an hour and a half and went to start it and the noise is gone! I cant believe it, I mean this thing always makes the sound at start up and only goes away when bike is hot and even when hot it will make a click here and there but i just let it run awhile and zip notta. I am gonna wait till tommorow morning to try it again and if there is no sound im pretty sure I fixed it for now. Keeping my fingers crossed! lol __________________ 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!!

04-30-2011, 01:05 PM	#2 (permalink)
MattT Honda Addict Join Date: Mar 2011 Posts: 113	There's an '03 manual here.

05-11-2011, 11:06 PM	#7 (permalink)
Wingman Honda Red Wing Rider Join Date: Mar 2010 Location: Rockford Illinois Posts: 933	Ok, I started it today about noon, so it was bone cold, and the initial start up noise is definately gone but I did notice a lil click every now and again after it was warm so we will see after I take it for a ride? Dont get me wrong!, My gauge pod does not work and I have no idea how many hours or miles are on my machine but im pretty sure it needs both the oil and cam chain replaced along with tensioner and guides. But right now funds are limited(I just used half a roll of black duct tape on the seat! lol) and im just trying to hump by until the economy picks back up and I can afford to really throw down on this thing.lol Oh and FYI, I was snoopin around on the Reconrider site and came across a posting about how to tell how worn out your chain and guides are. According to the poster you simply count out how many turns it takes on the adjuster clockwise until it stops. A brand new one stops in 2.5 turns and a really worn out one stops at 4 turns. Mine stops at just little over 3.25 turns so im thinking mine is **** near wore out! For now, Im just hoping for the best! __________________ 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!!

05-12-2011, 08:26 PM	#8 (permalink)
RidinDirty 03 Honda Rider Join Date: Mar 2010 Location: ramsey, il Posts: 57	Talked to the mechanic today and that's what's wrong with mine. It needs a new tensioner. It's like 70 bucks installed. Should be done tomorrow. __________________ BOILERMAKER L.U. 363 03 rincon 650 27" itp mudlites on 14" itp rims 03 foreman 450s 26" super swamper vampires winch that don't work

05-13-2011, 09:21 PM	#9 (permalink)
Wingman Honda Red Wing Rider Join Date: Mar 2010 Location: Rockford Illinois Posts: 933	Ridindirty, Let me know how that works out for you cause its only 47 bux for the part and if it fixes your problem I may just go and buy one myself. __________________ 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!!

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